Professional Documents
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Independent Demand
Dependent Demand
C(2)
B(4)
D(2)
E(1)
D(3)
F(2)
Inventory Models
Independent demand finished goods, items that are
ready to be sold
E.g. a computer
Dependent demand components of finished products
E.g. parts that make up the computer
12-4
Types of inventory
RAW MATERIAL: They are required to carry out production activities
uninterruptedly. The factors like the availability of raw materials and government
regulations, etc. too affect the stock of raw materials.
WORK-IN-PROGRESS: It is a stage of stocks between raw material & finished
goods. The greater the time taken in manufacturing, the more will be the amount
of work in progress.
FINISHED GOODS: These are the goods which are ready for the consumers. The
purpose of maintaining inventory is to ensure proper supply of goods to
consumers.
SPARES: Form a part of inventory. Some industries like transport will require
more spares than the other concerns. The costly spare parts like engines,
maintenance spares etc. are not discarded after use, rather they are kept in ready
position for further use.
Inventory Management
An efficient system of inventory management will
determine
What to purchase
How much to purchase
From where to purchase
Where to store
Objectives of Inventory
Management
Provide acceptable level of customer service (on
time delivery)
Allow cost-efficient operations
Minimize inventory investment
To avoid both over-stocking and under-stocking
of inventory
To ensure right quality goods at reasonable prices
Economies of Scale in Procurement : Buying raw materials in larger lot and holding
inventory is found to be cheaper for the company than buying frequent small lots. In
such cases one buys in bulk and holds inventories at the plant warehouse.
To protect against stock outs : Manufacturers use safety stock to protect against
uncertainties in either the demand or supply of an item. Delayed deliveries and
unexpected increases in demand increase the risk of shortages
Reduce Transit Cost and Transit Times : In case of raw materials being imported from
a foreign country or from a far away vendor within the country, one can save a lot in
terms of transportation cost buy buying in bulk.
There could be a lot of factors resulting in shipping delays and transportation too, which
can hamper the supply chain forcing companies to hold safety stock of raw material
inventories.
Long Lead and High demand items need to be held in Inventory : The particular
item is in high demand and short supply one can expect disruption of supplies. In such
cases it is safer to hold inventories and have control.
Purchase Cost : The actual price paid for the procurement of items is called purchase
cost. The purchase cost becomes relevant if a quantity discount is available. This
becomes an incentive to order greater quantities
Inventory Holding Cost : The holding, carrying or storage cost is the cost associated
with maintaining an inventory until it is used or sold. Holding or storage cost includes the
cost of maintaining storage & handling facilities, the cost of insuring the inventory, taxes
attributed to storage, costs associated with obsolescence etc.
Ordering cost : Each time a company places a purchase order with a supplier or a
production order, it incurs an ordering cost.
Set-Up Cost : The setup cost is the cost involved in changing a machine over to produce
a different part or item. While someone is adjusting a machine, it is idle and the company
incurs the additional costs.
Shortage Cost : The stock out or shortage cost occurs when the demand for an
item exceeds its supply. The cost associated with a stock out or shortage depends on
how the company handles the problem, the size of the shortage and how long the
shortage lasts .
Total Inventory Cost : If price discounts are available, then we should formulate total
inventory cost by taking sum of purchase cost (PC), Inventory Holding Cost (IHC),
Shortage Cost (SC) and Ordering Cost (OC). Thus, the total inventory cost; TC, is
given by
TC = PC + IHC + SC + OC
2DS
=
H
An EOQ Example
Determine optimal number of needles to order
D = 1,000 units
S = $10 per order
H = $.50 per unit per year
2DS
H
2(1,000)(10)
0.50
An EOQ Example
Economic Enterprises require 90,000 units of a certain item annually. The
cost per unit is Rs.3, the cost per purchase order Rs. 300 and the inventory
carrying cost Rs. 6 per unit per year. What is the Economics Order Quantity?
Q
*
2DS
H
EOQ
2 90,000 300
90,000 3,000 units
6
Lead time is the gap between when an order is placed and when it is
received.
Example : ABC Ltd. is a retailer of footwear. It sells 500 units of one of a famous
brand daily. Its supplier takes a week to deliver the order.
The inventory manager should place an order before the inventories drop below
3,500 units (500 units of daily usage multiplied with 7 days of lead time) in order
to avoid a stock-out
Maximum Stock Level = Reorder level + Reorder Quantity(Minimum Usage X Minimum Delivery Time)
Example : The maximum usage is 100 units per day and maximum lead
time is 10 days. The reorder quantity is 500 units. The minimum delivery
usage is 50 units per day and minimum delivery time is 5 days. Calculate
maximum level?
Reorder Level =
Maximum Usage X Maximum Lead Time
100X 10= 1000
Maximum Stock Level = Reorder Level+
Reorder Quantity-( Minimum Usage X
Minimum Lead Time)
=
1000+500-(50X5)
1250 units
JUST-IN-TIME PHILOSOPHY
Toyota Motor Company- first to implement fully
functioning and successful JIT system, in 1970s
An inventory system designed to produce efficient
output with minimum lead time at the lowest possible
cost, minimizing waste, with great consistency.
FOLLOWERS
Adopted by General Electrical in the USA in the 1980.
Some companies referred JIT with different names:
i. TOYOTA Toyota System
ii. IBM Continuous flow manufacturing
iii. GE- Management by sight
iv. HEWLETT- PACKARD- stockless production &
repetitive manufacturing system
JIT Goals
Eliminate disruptions
Make the system flexible
Reduce set up times & lead time
Minimize inventory
Eliminate waste
Increase productivity
Give the customer the products they want, when and
where they want them at the minimum cost
ADVANTAGES OF JIT
High quality
Flexibility
Reduced the cost of production
Less waste
Low warehouse cost
Reduced space requirements
Increased productivity
Improved vendor relations
DISADVANTAGES OF JIT
Time consuming
where,
cost of goods sold means sales minus gross profit and
avg. stock indicates yearly avg.(average of opening and closing inventory)
Analysis - it is used to measure the inventory management efficiency of a business.
- a higher value indicates better performance and lower value means inefficiency in
controlling inventory levels.