Chapter 6. Inventory Control Models
Chapter 6. Inventory Control Models
6-2
Learning Objectives
After completing this chapter, students will be able to:
6-3
Chapter Outline
6.1 Introduction
6.2 Importance of Inventory Control
6.3 Inventory Decisions
6.4 Economic Order Quantity: Determining
How Much to Order
6.5 Reorder Point: Determining When to Order
6.6 EOQ Without the Instantaneous Receipt
Assumption
6.7 Quantity Discount Models
6.8 Use of Safety Stock
6-4
Chapter Outline
6.9 Single-Period Inventory Models
6.10 ABC Analysis
6.11 Dependent Demand: The Case for Material
Requirements Planning
6.12 Just-in-Time Inventory Control
6.13 Enterprise Resource Planning
6-5
Introduction
Inventory is an expensive and important
asset to many companies.
Inventory is any stored resource used to
satisfy a current or future need.
Common examples are raw materials, work-
in-process, and finished goods.
Most companies try to balance high and low
inventory levels with cost minimization as a
goal.
Lower inventory levels can reduce costs.
Low inventory levels may result in stockouts and
dissatisfied customers.
6-6
Introduction
All organizations have some type of inventory
control system.
Inventory planning helps determine what
goods and/or services need to be produced.
Inventory planning helps determine whether
the organization produces the goods or
services or whether they are purchased from
another organization.
Inventory planning also involves demand
forecasting.
6-7
Introduction
Inventory planning and control
Planning on What
Forecasting Controlling
Inventory to Stock
Parts/Product Inventory
and How to Acquire
Demand Levels
It
Feedback Measurements
to Revise Plans and
Forecasts
Figure 6.1
6-8
Importance of Inventory Control
6-9
Importance of Inventory Control
Storing resources.
Seasonal products may be stored to satisfy
off-season demand.
Materials can be stored as raw materials, work-
in-process, or finished goods.
Labor can be stored as a component of
partially completed subassemblies.
Compensate for irregular supply and
demand.
Demand and supply may not be constant over
time.
Inventory can be used to buffer the variability.
6-10
Importance of Inventory Control
6-12
Inventory Cost Factors
ORDERING COST FACTORS CARRYING COST FACTORS
Developing and sending purchase orders Cost of capital
Processing and inspecting incoming
Taxes
inventory
Bill paying Insurance
Table 6.1
6-13
Inventory Cost Factors
Ordering costs are generally independent of
order quantity.
Many involve personnel time.
The amount of work is the same no matter the
size of the order.
Carrying costs generally varies with the
amount of inventory, or the order size.
The labor, space, and other costs increase as the
order size increases.
The actual cost of items purchased can vary
if there are quantity discounts available.
6-14
Economic Order Quantity
6-15
Economic Order Quantity
Assumptions:
1. Demand is known and constant.
2. Lead time is known and constant.
3. Receipt of inventory is instantaneous.
4. Purchase cost per unit is constant
throughout the year.
5. The only variable costs are the cost of
placing an order, ordering cost, and the cost
of holding or storing inventory over time,
holding or carrying cost, and these are
constant throughout the year.
6. Orders are placed so that stockouts or
shortages are avoided completely.
6-16
Inventory Usage Over Time
Inventory
Level
Order Quantity = Q =
Maximum Inventory Level
Minimum
Inventory
0
Time
Figure 6.2
6-17
Inventory Costs in the EOQ Situation
INVENTORY LEVEL
DAY BEGINNING ENDING AVERAGE
April 1 (order received) 10 8 9
April 2 8 6 7
April 3 6 4 5
April 4 4 2 3
April 5 2 0 1
Maximum level April 1 = 10 units
Total of daily averages = 9 + 7 + 5 + 3 + 1 = 25
Number of days = 5 Table 6.2
Average inventory level = 25/5 = 5 units
6-18
Inventory Costs in the EOQ Situation
Number of Ordering
Annual ordering cost orders placed cost per
per year order
D
Co
Q
6-19
Inventory Costs in the EOQ Situation
Average Carrying
Annual holding cost inventory cost per unit
per year
Q
Ch
2
6-20
Inventory Costs in the EOQ Situation
Figure 6.3
Optimal Order Quantity
Order
Quantity 6-21
Finding the EOQ
According to the graph, when the EOQ assumptions
are met, total cost is minimized when annual
ordering cost equals annual holding cost.
D Q
Co Ch
Q 2
Solving for Q
2 DC o Q 2C h
2 DC o
Q2
Ch
2 DC o
Q EOQ Q *
Ch
6-22
Economic Order Quantity (EOQ) Model
Summary of equations:
D
Annual ordering cost C o
Q
Q
Annual holding cost C h
2
2 DC o
EOQ Q *
Ch
6-23
Sumco Pump Company
2 DC o 2(1,000 )(10 )
Q
*
40,000 200 units
Ch 0.50
6-24
Sumco Pump Company
6-25
Purchase Cost of Inventory Items
Total inventory cost can be written to include the
cost of purchased items.
Given the EOQ assumptions, the annual purchase
cost is constant at D C no matter the order
policy, where
C is the purchase cost per unit.
D is the annual demand in units.
At times it may be useful to know the average
dollar level of inventory:
(CQ )
Average dollar level
2
6-26
Purchase Cost of Inventory Items
Inventory carrying cost is often expressed as an
annual percentage of the unit cost or price of the
inventory.
This requires a new variable.
C h IC
2 DC o
thus, Q
*
IC
6-27
Sensitivity Analysis with the
EOQ Model
The EOQ model assumes all values are know and
fixed over time.
Generally, however, some values are estimated or
may change.
Determining the effects of these changes is
called sensitivity analysis.
Because of the square root in the formula,
changes in the inputs result in relatively small
changes in the order quantity.
2 DC o
EOQ
Ch
6-28
Sensitivity Analysis with the
EOQ Model
In the Sumco Pump example:
2(1,000 )(10 )
EOQ 200 units
0.50
2(1,000 )( 40 )
EOQ 400 units
0.50
6-29
Reorder Point:
Determining When To Order
Once the order quantity is determined, the
next decision is when to order.
The time between placing an order and its
receipt is called the lead time (L) or
delivery time.
When to order is generally expressed as a
reorder point (ROP).
dL
6-30
Procomp’s Computer Chips
6-31
Reorder Point Graphs
Figure 6.4
6-32
EOQ Without The Instantaneous
Receipt Assumption
When inventory accumulates over time, the
instantaneous receipt assumption does not apply.
Daily demand rate must be taken into account.
The revised model is often called the production
run model.
6-34
Annual Carrying Cost for
Production Run Model
Maximum inventory level
(Total produced during the production run)
– (Total used during the production run)
(Daily production rate)(Number of days production)
– (Daily demand)(Number of days production)
(pt) – (dt)
Q d
Average inventory 1
2 p
and
Q d
Annual holding cost 1 C h
2 p
6-36
Annual Setup Cost for
Production Run Model
Setup cost replaces ordering cost when a product is
produced over time.
D
Annual setup cost C s
Q
replaces
D
Annual ordering cost C o
Q
6-37
Determining the Optimal
Production Quantity
By setting setup costs equal to holding costs, we
can solve for the optimal order quantity
Q d D
1 C h C s
2 p Q
2 DC s
Q*
d
C h 1
p
6-38
Production Run Model
Summary of equations
Q d
Annual holding cost 1 C h
2 p
D
Annual setup cost C s
Q
2 DC s
Optimal production quantity Q *
d
C h 1
p
6-39
Brown Manufacturing
6-40
Brown Manufacturing Example
2 DC s Q
1. Q
*
2. Production cycle
d p
C h 1
p 4,000
50 days
80
2 10,000 100
Q
*
60
0 .5 1
80
2,000 ,000
16,000 ,000
0.5 1
4
4,000 units
6-41
Quantity Discount Models
Quantity discounts are commonly available.
The basic EOQ model is adjusted by adding in the
purchase or materials cost.
Table 6.3
6-44
Quantity Discount Models
Total cost curve for the quantity discount model
Total TC Curve for Discount 3
Cost
$ TC Curve for
Discount 1
Figure 6.6
0 1,000 2,000
Order Quantity
6-45
Brass Department Store
Brass Department Store stocks toy race cars.
Their supplier has given them the quantity
discount schedule shown in Table 6.3.
Annual demand is 5,000 cars, ordering cost is $49, and
holding cost is 20% of the cost of the car
The first step is to compute EOQ values for each
discount.
(2)(5,000 )( 49 )
EOQ1 700 cars per order
(0.2)(5.00 )
(2)(5,000 )( 49 )
EOQ2 714 cars per order
(0.2)( 4.80 )
(2)(5,000 )( 49 )
EOQ3 718 cars per order
(0.2)( 4.75 )
6-46
Brass Department Store Example
Q1 700
Q2 1,000
Q3 2,000
6-47
Brass Department Store
6-49
Use of Safety Stock
The basic ROP equation is
ROP d L
d daily demand (or average daily demand)
L order lead time or the number of
working days it takes to deliver an order
(or average lead time)
6-50
Use of Safety Stock
Figure 6.7
6-51
ROP with Known Stockout Costs
6-52
Safety Stock with Unknown
Stockout Costs
There are many situations when stockout costs
are unknown.
An alternative approach to determining safety
stock levels is to use a service level.
A service level is the percent of time you will not
be out of stock of a particular item.
6-53
Safety Stock with the Normal
Distribution
ROP = (Average Demand During Lead Time) + ZσdLT
Where:
6-54
Hinsdale Company
Inventory demand during lead time is normally
distributed.
Mean demand during lead time is 350 units with a
standard deviation of 10.
The company wants stockouts to occur only 5%
of the time.
6-55
Hinsdale Company Example
X SS
From Appendix A we find Z 1.65
Solving for safety stock:
5% Area of
Normal Curve
Figure 6.9 SS
350 X?
6-56
Hinsdale Company
Different safety stock levels will be generated for
different service levels.
However, the relationship is not linear.
You should be aware of what a service level is costing in
terms of carrying the safety stock in inventory.
The relationship between Z and safety stock can
be developed as follows:
X
1. We know that Z
4. So we have
2. We also know that SS X – SS Z
Z(10)
SS
3. Thus Z
6-57
Hinsdale Company
Safety Stock at different service levels
SERVICE LEVEL Z VALUE FROM SAFETY STOCK
(%) NORMAL CURVE TABLE (UNITS)
90 1.28 12.8
91 1.34 13.4
92 1.41 14.1
93 1.48 14.8
94 1.55 15.5
95 1.65 16.5
96 1.75 17.5
97 1.88 18.8
98 2.05 20.5
99 2.33 23.3
Table 6.5
99.99 3.72 37.2
6-58
Hinsdale Company
Service level versus annual carrying costs
This graph was
developed for a
specific case, but
the general shape of
the curve is the
same for all service-
level problems.
Figure 6.9
6-59
Calculating Lead Time Demand
and Standard Deviation
There are three situations to
consider:
Demand is variable but lead time is
constant.
Demand is constant but lead time is
variable.
Both demand and lead time are variable.
6-60
Calculating Lead Time Demand
and Standard Deviation
Demand is variable but lead time is
constant:
Where:
6-61
Calculating Lead Time Demand
and Standard Deviation
Demand is constant but lead time is
variable:
Where:
6-62
Calculating Lead Time Demand
and Standard Deviation
Both demand and lead time are
variable.
6-63
Hinsdale Company
Suppose for product SKU F5402, daily demand is
normally distributed, with a mean of 15 units and a
standard deviation of 3. Lead time is exactly 4 days.
To maintain a 97% service level, what is the ROP,
and how much safety stock should be carried?
ROP = 15(4)+1.88(3*2)
= 60 + 11.28
=71.28
ROP = 25(6)+2.05(25*3)
= 150+153.75
=303.75
ROP = 100+1.55(40.99)
= 163.53
6-66
Calculating Annual Holding
Cost with Safety Stock
Under standard assumptions of EOQ,
average inventory is just Q/2.
So annual holding cost is: (Q/2)*Ch.
This is not the case with safety stock
because safety stock is not meant to
be drawn down.
6-67
Calculating Annual Holding
Cost with Safety Stock
Total annual holding cost = holding
cost of regular inventory + holding
cost of safety stock
Where:
THC = total annual holding cost
Q = order quantity
Ch = holding cost per unit per year
SS = safety stock
6-68
ABC Analysis
The purpose of ABC analysis is to divide the
inventory into three groups based on the overall
inventory value of the items.
Group A items account for the major portion of
inventory costs.
Typically about 70% of the dollar value but only 10% of
the quantity of items.
Forecasting and inventory management must be done
carefully.
Group B items are more moderately priced.
May represent 20% of the cost and 20% of the quantity.
Group C items are very low cost but high volume.
It is not cost effective to spend a lot of time managing
these items.
6-69
Summary of ABC Analysis
A 70 10 Yes
B 20 20 In some cases
C 10 70 No
Table 6.8
6-70
Dependent Demand: The Case for
Material Requirements Planning
6-71
Dependent Demand: The Case for
Material Requirements Planning
6-72
Just-in-Time (JIT) Inventory
Control
To achieve greater efficiency in the
production process, organizations have
tried to have less in-process inventory on
hand.
This is known as JIT inventory.
The inventory arrives just in time to be
used during the manufacturing process.
One technique of implementing JIT is a
manual procedure called kanban.
6-73
Just-in-Time Inventory Control
6-74
4 Steps of Kanban
1. A user takes a container of parts or inventory
along with its C-kanban to his or her work area.
When there are no more parts or the container is
empty, the user returns the container along with
the C-kanban to the producer area.
2. At the producer area, there is a full container of
parts along with a P-kanban.
The user detaches the P-kanban from the full
container and takes the container and the C-
kanban back to his or her area for immediate
use.
6-75
4 Steps of Kanban
3. The detached P-kanban goes back to the
producer area along with the empty container
The P-kanban is a signal that new parts are to be
manufactured or that new parts are to be placed
in the container and is attached to the container
when it is filled .
4. This process repeats itself during the typical
workday.
P-kanban C-kanban
and and
Container Container
4 1
3 2
Figure 6.16
Drawbacks to ERP:
The software is expensive to buy and costly to
customize.
Small systems can cost hundreds of thousands of
dollars.
Large systems can cost hundreds of millions.
The implementation of an ERP system may
require a company to change its normal
operations.
Employees are often resistant to change.
Training employees on the use of the new
software can be expensive.