Chapter 13

Inventory Management
 Lecture Outline
• Elements of Inventory Management
• Inventory Control Systems
• Economic Order Quantity Models
• Quantity Discounts
• Reorder Point
• Order Quantity for a Periodic Inventory System

Copyright 2011 John Wiley & Sons, Inc. 13-2

 What Is Inventory?
• Stock of items kept to meet future demand
• Purpose of inventory management
• how many units to order
• when to order

Copyright 2011 John Wiley & Sons, Inc. 13-3

 Supply Chain Management
• Bullwhip effect
• demand information is distorted as it moves away
from the end-use customer
• higher safety stock inventories to are stored to
compensate
• Seasonal or cyclical demand
• Inventory provides independence from vendors
• Take advantage of price discounts
• Inventory provides independence between
stages and avoids work stoppages

Copyright 2011 John Wiley & Sons, Inc. 13-4

 Quality Management in the Supply Chain

• Customers usually perceive quality service as

availability of goods they want when they want
them
• Inventory must be sufficient to provide high-
quality customer service in QM

Copyright 2011 John Wiley & Sons, Inc. 13-5

 Types of Inventory
• Raw materials
• Purchased parts and supplies
• Work-in-process (partially completed) products
(WIP)
• Items being transported
• Tools and equipment

Copyright 2011 John Wiley & Sons, Inc. 13-6

 Two Forms of Demand
• Dependent
• Demand for items used to produce final
products
• Tires for autos are a dependent demand item
• Independent
• Demand for items used by external customers
• Cars, appliances, computers, and houses are
examples of independent demand inventory

Copyright 2011 John Wiley & Sons, Inc. 13-7

 Inventory Costs
• Carrying cost
• cost of holding an item in inventory
• Ordering cost
• cost of replenishing inventory
• Shortage cost
• temporary or permanent loss of sales when
demand cannot be met

Copyright 2011 John Wiley & Sons, Inc. 13-8

 Inventory Control Systems

• Continuous system (fixed-order-quantity)

• constant amount ordered when inventory declines to
predetermined level
• Periodic system (fixed-time-period)
• order placed for variable amount after fixed passage
of time

Copyright 2011 John Wiley & Sons, Inc. 13-9

 ABC Classification
• Class A
• 5 – 15 % of units
• 70 – 80 % of value
• Class B
• 30 % of units
• 15 % of value
• Class C
• 50 – 60 % of units
• 5 – 10 % of value

Copyright 2011 John Wiley & Sons, Inc. 13-10

 ABC Classification
PART UNIT COST ANNUAL USAGE
1 $ 60 90
2 350 40
3 30 130
4 80 60
5 30 100
6 20 180
7 10 170
8 320 50
9 510 60
10 20 120

Copyright 2011 John Wiley & Sons, Inc. 13-11

 ABC Classification
TOTAL % OF TOTAL % OF TOTAL
PART VALUE VALUE QUANTITY % CUMMULATIVE
9 $30,600 35.9 6.0 6.0
8 16,000 18.7 5.0 11.0
2 14,000 16.4 4.0
A 15.0
1 5,400 6.3 9.0 24.0
4 4,800 5.6 6.0 B 30.0
3 3,900 4.6 10.0 40.0
6 3,600 4.2 18.0 58.0
5 3,000 3.5 13.0 71.0
10 2,400 2.8 12.0 C 83.0
7 1,700 2.0 17.0 100.0
$85,400

Example 10.1
Copyright 2011 John Wiley & Sons, Inc. 13-12
 ABC Classification

% OF TOTAL % OF TOTAL
CLASS ITEMS VALUE QUANTITY
A 9, 8, 2 71.0 15.0
B 1, 4, 3 16.5 25.0
C 6, 5, 10, 7 12.5 60.0

Example 10.1
Copyright 2011 John Wiley & Sons, Inc. 13-13
 Economic Order Quantity
(EOQ) Models
• EOQ
• optimal order quantity that will minimize
total inventory costs
• Basic EOQ model
• Production quantity model

Copyright 2011 John Wiley & Sons, Inc. 13-14

 Assumptions of Basic EOQ Model

• Demand is known with certainty and is constant

over time
• No shortages are allowed
• Lead time for the receipt of orders is constant
• Order quantity is received all at once

Copyright 2011 John Wiley & Sons, Inc. 13-15

 Inventory Order Cycle

Order quantity, Q
Demand Average
rate inventory
Inventory Level

Q
2

Reorder point, R

0 Lead Lead Time

time time
Order Order Order Order
placed receipt placed receipt

Copyright 2011 John Wiley & Sons, Inc. 13-16

 EOQ Cost Model

Co - cost of placing order D - annual demand

Cc - annual per-unit carrying cost Q - order quantity

CoD
Annual ordering cost =
Q

CcQ
Annual carrying cost =
2

Co D CcQ
Total cost = +
Q 2

Copyright 2011 John Wiley & Sons, Inc. 13-17

 EOQ Cost Model

Deriving Qopt Proving equality of

costs at optimal point
CoD CcQ
TC = +
Q 2 C oD CcQ
=
TC Co D
Cc Q 2
=– +
Q Q 2
2 2CoD
Q =2
C0D Cc Cc
0=– +
Q2 2
2CoD
2CoD Qopt =
Qopt = Cc
Cc

Copyright 2011 John Wiley & Sons, Inc. 13-18

 EOQ Cost Model
Annual
cost ($) Total Cost
Slope = 0

CcQ
Minimum Carrying Cost =
2
total cost

CoD
Ordering Cost =
Q

Optimal order Order Quantity, Q

Qopt

Copyright 2011 John Wiley & Sons, Inc. 13-19

 EOQ Example

Cc = $0.75 per gallon Co = $150 D = 10,000 gallons

2CoD CoD CcQ

Qopt = TCmin = +
Cc Q 2
2(150)(10,000) (150)(10,000) (0.75)(2,000)
Qopt = TCmin = +
(0.75) 2,000 2

Qopt = 2,000 gallons TCmin = $750 + $750 = $1,500

Orders per year = D/Qopt Order cycle time = 311 days/(D/Qopt)

= 10,000/2,000 = 311/5
= 5 orders/year = 62.2 store days

Copyright 2011 John Wiley & Sons, Inc. 13-20

 Reorder Point
• Inventory level at which a new order is placed

R = dL
where

d = demand rate per period

L = lead time

Copyright 2011 John Wiley & Sons, Inc. 13-21

 Reorder Point

Demand = 10,000 gallons/year

Store open 311 days/year
Daily demand = 10,000 / 311 = 32.154
gallons/day
Lead time = L = 10 days

R = dL = (32.154)(10) = 321.54 gallons

Copyright 2011 John Wiley & Sons, Inc. 13-22

 Safety Stock
• Safety stock
• buffer added to on hand inventory during lead time
• Stockout
• an inventory shortage
• Service level
• probability that the inventory available during lead
time will meet demand
• P(Demand during lead time <= Reorder Point)

Copyright 2011 John Wiley & Sons, Inc. 13-23

 Variable Demand With Reorder Point

Q
Inventory level

Reorder
point, R

0
LT LT
Time

Copyright 2011 John Wiley & Sons, Inc. 13-24

 Reorder Point With Safety Stock
Inventory level

Q
Reorder
point, R

Safety Stock
0
LT LT
Time

Copyright 2011 John Wiley & Sons, Inc. 13-25

 Periodic Inventory System

Copyright 2011 John Wiley & Sons, Inc. 13-26