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Inventory Management
Suman Niranjan
Inventory
Inventory: a stock or store of
goods Independent
Demand
A Dependent
Demand
B C
(4) (2)
D E D F(2)
(2) (1) (3)
2
Independent demand is uncertain.
Dependent demand is certain.
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
3
Key Inventory Terms
Lead time: time interval between ordering
and receiving the order
Holding (carrying) costs: cost to carry an
item in inventory for a length of time, usually
a year
Ordering costs: costs of ordering and
receiving inventory
Shortage costs: costs when demand exceeds
supply
4
Types of Inventories
6
Little’s Law
Little’s Law:
The average amount of inventory in a system is
equal to the product of the average demand rate
and the average time a unit spends in the
system
Example
If a unit is in system for an average of 10 days
and the demand for each day is 5 units, the
average inventory:
5 units/day * 10 days = 50 units
7
Objective of Inventory Control
To achieve satisfactory levels of customer service
while keeping inventory costs within reasonable
bounds
Level of customer service
Costs of ordering and carrying inventory
Two fundamental decisions of inventory control
When to order; how much to order
Days of inventory on-hand
Higher – excess inventory; Lower – risk of running out
10
Inventory Counting Systems
(Cont’d)
Two-Bin System - Two containers of
inventory; reorder when the first is empty
Universal Bar Code - Bar code
printed on a label that has
information about the item
to which it is attached
RFID tags
214800 232087768
11
ABC Classification System
B- mod. important
C- least important H
A
igh
Annual B
$ value
of
Lo C
w 12
Low H
Percentage ofigh
Items
Inventory Counting
Increase Customer service
Improve Operations
Cycle Counting
Purpose is to reduce the discrepancy amounts
indicated by the records and actual inventory
A physical count of items in inventory
Cycle counting management
How much accuracy is needed?
When should cycle counting be performed?
Who should do it?
13
Economic Order Quantity
Models
Basic Economic order quantity (EOQ) model
The order size that minimizes total annual cost
Economic production model
Quantity discount model
14
Assumptions of EOQ Model
Only one product is involved
Annual demand requirements known
15
The Inventory Cycle
Reorder
point
T
Receiv Plac Receiv Plac Receiv ime
e e e e e
order orde order orde order 16
Lead
time
Total Cost
Annual Annual
Total cost carryi + orderi
ng ng
Q DS
TC H +
2 Q
=
TC: Total Cost
Q: Order Quantity in Units
H: Holding Cost Per Unit
D: Demand, Usually in Units Per Year
S: Ordering Cost
17
Cost Minimization Goal
The Total-Cost Curve is U-
Shaped
Annual
Cost
Ordering
Costs
Order
QO(optimal order
quantity) Quantity 18
(Q)
Deriving the EOQ
Using calculus, we take the derivative of the
total cost function and set the derivative
(slope) equal to zero and solve for Q.
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Minimum Total Cost
The total cost curve reaches its minimum
where the carrying and ordering costs are
equal.
Q DS
H =
2 Q
20
Example 2
A local distributor for a national tire company
expects to sell approximately 9,600 steel-
belted radial tires of a certain size and tread
design next year. Annual carrying cost is $16
per tire, and ordering cost is $75. The
distributor operates 288 days a year.
a) What is the EOQ?
b) How many times per year does the store
reorder?
c) What is the length of an order cycle?
d) What is the total annual cost if the EOQ
quantity is ordered?
21
Economic Production Quantity
(EPQ)
Production done in batches or lots
Capacity to produce a part exceeds the part’s
usage or demand rate
Assumptions of EPQ are similar to EOQ
except orders are received incrementally
during production
22
Economic Production Quantity
Assumptions
Only one item is involved
Annual demand is known
No quantity discounts
23
EOQ with Incremental Inventory
Replenishment
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Economic Run Size
25
Example 4
A toy manufacturer uses 48,000 rubber
wheels per year for its popular dump truck
series. The firm makes its own wheels, which
it can produce at a rate of 800 per day. The
toy trucks are assembled uniformly over the
entire year. Carrying cost is $1 per wheel a
year. Setup cost for a production run of
wheels is $45. The firm operates 240 days
per year. Determine the
Optimal run size.
Minimum total annual cost for carrying and
setup.
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Cycle time for the optimal run size.
Run time.