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McGraw-Hill/Irwin
AgendaOrder Point
Inventory Control Methods
11-3
Basic Concepts
inventoriesprimarily
influenced by factors outside of company
decisions (e.g. random variation)
Demand forecasts estimate the average usage rate
and pattern of variation
Dependent-demand
inventoriesinfluenced
mainly by internal factors within the firms control
11-4
11-5
Inventory Management
Issues
11-6
Parameters:
11-7
Inventory Management
Issues
11-8
Inventory Management
Issues
Implementing Changes in Managing
Inventorymaking the appropriate changes at
the right time is critical
More formalized change management system
is required as the scope of the business
increases
11-9
Inventory-Related Costs
A
Q
TAC ( )C P ( )C H
Q
2
Total Costs
Ordering Costs
Inventory
Holding Costs
11-11
11-12
TBO
EOQ
D
11-13
TV Retailer example:
_________
EOQ = 2*Cp*A/CH
If A = 1250 units/year
Cp = 6.25 $/order (or setting up)
CH = 25 $/unit/year
______________
EOQ = 2*6.25*1250/25 = 25
When we buy tvs we should buy them in lots of 25.
11-14
11-15
Example
Example (Cont.)
________________
a) Q* = 2*4000*30/(.08*90) = 182.6
b) TSC = 4000/182.6*30 +
182.6/2*(.08*90) = 652.6 + 652.6
= 20*40 = 800
Additional area needed = 112.9 m2
11-17
Example
a)
b)
11-18
Example (cont.)
a)
b)
__________________
Q* = 2*150/0.25 = 7348.5
TAC = 7348.5/2*.25 +
250*180/7348.5*150 = 918.6 + 918.6
= 1837.1
11-19
Q,R rule
When
Inventory level
Reorder point
Safety stock
R
Time
Lead time
11-21
SL 100 (100 / Q)
d max
P(d )(d R)
d R 1
11-22
Stockout Probability
With a lead time
of one day, 95%
of cycles will
experience
demand for 7 or
fewer units
Safety stock of 7
units will provide 5%
chance of stockout
during a one day
lead time
Sum of demand
probability is
0.05 (5%)
11-23
Sum = 0.35
11-24
0.05
20
0.15
21
0.2
22
0.3
23
0.1
24
0.15
25
0.05
26
Olaslk
Talep
0.05
20
0.15
21
0.2
22
0.3
23
0.1
24
0.15
25
0.05
26
If we take our reorder point as 22, what is our expected units short (the
demand that cant be filled)?
If demand is 20, 21, or 22, we dont have any units short
Reorder point
Probability of
at least one
stockout
during cycle
Expected
number of
stockouts per
cycle
11-27
R = davg + S
(average deman during lead time davg
+ Safety Stock S)
S = Z d
R = davg + Zd
Z, standart deviation multiple corresponding to
relevant stockout probablility according to normal
distribution
(Example% 5 Stockout = 95% SL Z=1,645).
d ... Standard deviation in demand, during lead time
11-28
Safety stock = Zd
Reorder point = mean demand during replenishment lead time + Zd
Z = appropriate value from standard normal table
d = standard deviation of demand during replenishment lead time
11-29
Example
Q = 5;
d = 1.5;
Example
Q = 5; d = 1.5
SL = 95%
Example:
D = Annual demand 1000
LT=15 days
Q = 200
Service Level = 95 % (.95)
Annual number of days= 250 d=50 units
Average daily demand=1000/250 = 4 /day
R = d + Z d = 4*15 + Z(50)
E(Z)=(1-.95)200/50 = 0.2 from tables
Z = 0.49
R = 4(15) + 0.49*50 = 84.5
11-34
Example (Cont.)
Policy:
When inventory level gets to 85 or less then order 200.
What is the expected number of units short per order?
E(Z) d = 0.2 * 50 = 10
How many orders per year?
(1000/200)= 5
Total number of units short?
10*5 = 50 (Service level is 95%; 950/1000)
11-35
d D m
d L D L2
Safety Stock Z D m
lead time
demand period
2
D
11-36
MAD
11-37
Multi-Item Management
Management attention should be focused on
the most important items
ABC analysis segments the inventoried items
according to annual cost volume usage
(unit cost x annual usage)
A items are the most important
This
ABC Analysis
3 classes
A
ABC Analizi
Dollar Usage
Category # of items % of items % of $ use
A
15
11
84%
B
25
15
15
C
88
74
1
Total
128
100
100
11-40
11-41
Criticality
I
II
III Total
2
12 1
15
1
19 5
25
2
17 69 88
5
48 75 128
11-42
%
%
of items of $ use
11
78%
13
12
76
10
100
100
11-43
BB
CC
Counting
Frequency
monthly
Every six
months
yearly
Order quantity
Low
quatity
EOQ
Large quantity
Safety stock
High for
critical
items
High for
critical items
Low or none
Every 6
months
yearly
Reclassification Every 6
months
11-44
Principles
The difference between dependent and independent
demand must serve as the first basis for determining
appropriate inventory management procedures.
Organizational criteria must be clearly established
before we set safety stock levels and measure
performance.
A sound basic independent demand system must be
in place before attempting to implement advanced
techniques.
11-45
Principles
Savings in inventory-related costs can be
achieved by a joint determination of the order
point and order quantity parameters.
All criteria should be taken into account in
classifying inventory items for management
priorities.
The functions of inventory are useful principles to
apply in determining whether or not inventory
reductions can be made.
11-46
Quiz Chapter 11