EES 402 Notes
EES 402 Notes
This is the use of mathematical models to determine the best inventory level to maintain and the
An inventory is any stock of economic resources that is stored for future use. Examples are food
Some types of inventories maintained by organizations for their production systems include raw
Purpose of inventory
In such a case inventories are kept as a buffer that can be used until late deliveries arrive.
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5. Saving and ordering costs
Ordering in large quantities reduces the number of times that an order must be placed and
processed. Since a fixed cost is associated with placing each order, the fewer times that
6. Bargaining power
Inventories improve the bargaining power of a firm with a supplier by making the firm
TERMINOLOGY
P. M is
1. Retail model versus production model
ordering
Retail model are those in which the replenishment inventories are purchased from
suppliers outside the firm. The model assumes that inventories are replenished
Production model are those in which the replenishment inventories are produced
internally by the firm. The model assumes that the replenishment occurs over time.\
2. Demand versus depletion of inventory. Demand is the use depletion is the rate
of use
Demand refers to the use of stock while depletion is the rate of use of stock.
The rate of use of the stock determines the depletion rate. The demand on the stock may
be known with certainty and such model is referred to as deterministic demand model.
The rate of demand could be constant or fluctuating. A constant rate of demand for
example could be five units per time period which reduces the inventory and equal steps
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Inventory level
Constant Demand
Time
Inventory level
Fluctuating
Demand
Time
3. Lead time versus re-order points
order is initiated.
Lead time is the time between the initiation of the replenishment activity and the receipts
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N/B as in the demand, lead time can be constant and known with certainty or can be
probabilistic in nature.
4. Ordering policy
a) The order- point system Monitor stock and then order what you always
order to fill you order. Predetermined order
This is often referred to as the perpetual inventory system where a perpetual inventory
point no matter the time
record is maintained and reviewed on a continual basis. When the inventory reaches a
items is initiated.
The system is used when the number of items demanded per transaction is relatively
Inventories are not reviewed continually but rather checks are made at predetermined
fixed intervals of time. The replenishment inventories ordered vary from time to time i.e.
the inventory at hand is compared with the desired inventory level and the difference
Inventory shortages occur when demand exceeds the quantity of inventory at hand.
Shortages may either be accidental or planned; regardless of the cause a policy must be
developed that addresses the problem of shortages. A model that takes into considerations
received. On the other hand models in which shortages are not back-ordered are referred
6. System structure
Single stage systems is one in which the inventories are used to directly satisfy demand
e.g. inventories that a retailer holds to meet consumer demand, medical supplies that a
Multiple stage systems are those in which multiple inventory stock points exist e.g. the
COST CRITERIA
The major problem of inventory management is determining the appropriate inventory level.
This problem is related to the problem of how much to order and when to order. If a commodity
is ordered frequently then the costs of ordering are high. On the other hand ordering more units
less frequently saves on ordering cost but increases the expenses of keeping a large inventory.
The most common criteria used in inventory analysis or management are the inventory related
costs criteria whose aim is to minimize the total costs of inventory. This includes;
These costs are incurred whenever an inventory replenishment activity incurs. It includes all the
expenses of placing orders such as decrial and administrative costs, processing and expediting
costs, recovering and inspection costs, accounting and auditing costs e.t.c
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It is assumed that the ordering costs are constant and independent of the order size.
In a production model ordering coats are referred to as set-up costs while an order size is
2. Carrying cost / storage cost/ holding costs Direct cost associated with storing cost
Seen as an opportunity cost like holding money =amount of
cost
Implicit cost is indirect costs
These are the costs associated with holding a given level of inventory over specific time period.
They consist of explicit and implicit costs associated with maintaining and owning inventory.
This include the opportunity cost of money invested, the cost of physical storage (rent, heating,
It also includes depreciation; insurance e.t.c. carrying costs are expressed as a cost per unit of
This is the cost that occurs when an item cannot be supplied upon demand. The size of the
cost depends on whether back ordering is permitted. If not, then an inventory shortage will
result in the permanent loss of sales for items demanded but not available. An additional
good will cost will be incurred if the clients take future business elsewhere. If back ordering
is permitted the relevant shortage costs are the clerical and administrative costs associated
Generally shortage costs are assumed to be fixed per shortage regardless of the size shortage
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4. Purchase/ production costs
This is the direct cost associated with the actual purchase production of an item. In this case the
cost per unit is assumed to be constant regardless of the quantity purchase or produced.
However, these assumptions will be relaxed if quality or price discounts are allowed depending
Assumption
2. The lead time is zero i.e. an order is received at the time/instant it is placed.
5. The inventory replenishment is instantaneous i.e. the entire order is received in a single
batch.
Retail model
Ro
T1 T2 Page 7 of 20 Time
Total cost =ordering cost + holding
cost
N/B
The downward sloping line indicates that the inventory is being used at a constant rate over
time.
Since the lead time is zero and the replenishment is instantaneous then the re-order point R is
determined automatically when the inventory reaches zero. The quantity ordered at each
replenishment point is Q.
The objective is to determine the optimal order quantity Qx so that the total inventory costs
are minimized.
As the order quantity rises, fewer orders are necessary and hence the ordering costs will
decrease i.e the bigger the quantity Q, the less are the ordering costs.
On the other hand as the order size increases more units are held in inventory and hence the
Since the ordering costs and carrying costs respond in opposite manner as the order size
increases, the optimal order quantity is the point where the ordering costs are equal to the
carrying costs.
Cost
s
Total Costs
Carrying costs
Ordering costs
Qx Q
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Let 𝐶𝑜 be the ordering cost per order.
The decision variable for which a solution is sought is the order size (Q)
𝑫
Since the demand D/time period is known, the number of orders is given by 𝑸
𝐷
𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒; 𝑇𝑂𝐶 = 𝐶𝑜 𝑋
𝑄
𝑇. 𝐶. 𝐶 =
𝑐𝑎𝑟𝑟𝑦𝑖𝑛𝑔 𝑐𝑜𝑠𝑡𝑠 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑝𝑒𝑟 𝑡𝑖𝑚𝑒 𝑝𝑒𝑟𝑖𝑜𝑑 × 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑛𝑜. 𝑜𝑓 𝑢𝑛𝑖𝑡𝑠 ℎ𝑒𝑙𝑑 𝑖𝑛 𝑖𝑛𝑣𝑒𝑛𝑡𝑜𝑟𝑦.
1
𝑋𝑇1 𝑋𝑄
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑖𝑛𝑣𝑒𝑛𝑡𝑜𝑟𝑦 = 2
𝑇1
𝑄
=
2
𝑄
𝑇𝐶𝐶 = 𝐶𝑐 𝑋
2
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𝐷 𝑄
𝑀𝑖𝑛 𝑇𝐶 = 𝐶𝑜 𝑋 + 𝐶𝑐 𝑋
𝑄 2
𝜕𝑇𝐶 𝐷 𝐶𝑐
= −𝐶𝑜 2 + = 0
𝜕𝑄 𝑄 2
𝐷 𝐶𝑐
𝐶𝑜 𝑋 =
𝑄2 2
𝑄 2 𝐶𝑐 = 2𝐶𝑜 𝐷
2𝐶𝑜 𝐷
𝑄2 =
𝐶𝑐
2𝐶𝑜 𝐷
𝐸𝑂𝑄 = 𝑄 ∗ = √
𝐶𝑐
𝐷 𝐷
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑜𝑟𝑑𝑒𝑟𝑠 = =
𝑄∗ 2𝐶𝑜
√
𝐶𝑐
𝐷𝐶𝑐
=√
2𝐶𝑜
1
𝑇=
𝑁∗
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𝑻 = √𝟐𝑪𝒐 𝑪𝒄 𝑫
Example;
𝑆𝑢𝑝𝑝𝑜𝑠𝑒 𝐶𝑜 = $ 20.
2𝑋20𝑋365
1. 𝑄 ∗ = √ 100
= 12.083
≃ 12
365
2. 𝑁 ∗ = ≃ 30
12
1 1
3. 𝑇𝑐 = = = 0.03 𝑦𝑒𝑎𝑟𝑠
𝑁∗ 30
𝐷 100𝑋12 7300
𝑇𝑐 = 𝐶𝑜 𝑋 + = + 600
𝑄 2 12
𝑇𝑐 ≃ 1200
Alternatively ;
𝑇𝑐 = √2𝐶𝑜 𝐶𝑐 𝐷 = √2𝑋100𝑋365𝑋20
𝑇𝑐 ≃ 1208
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EOQ MODEL WITH QUANTITY DISCOUNTS
So far we have been silent about the unit purchasing price. It has been assumed constant. In
practice however, it’s common for suppliers to allow purchase price discount if the
The approach for evaluating the impact of a single price discount is to compare the TC for
the optimal inventory policy without discounts with the TC if the discount is accepted.
The TC equation for evaluating the discounts must include the purchasing costs per time
period
𝐷 𝑄∗
𝐿𝑒𝑡 𝑇𝑐 𝑄 ∗ = 𝐶𝑜 + 𝐶𝑐 + 𝐷. 𝑃(𝑁𝑜 𝑑𝑖𝑠𝑐𝑜𝑢𝑛𝑡)
𝑄∗ 2
𝐷 𝑄
𝑇𝑐 (𝑄 ∗ ) = 𝐶𝑜 + 𝐶𝑐 + 𝐷. 𝑃(𝑑𝑖𝑠𝑐𝑜𝑢𝑛𝑡)
𝑄 2
If 𝑇𝑐 𝑄 < 𝑇𝑐 𝑄 ∗ then we accept the discount otherwise we reject the discount. In other words
Consider the previous example, suppose a discount of 2% is offered at the normal purchase
𝐷𝑖𝑠𝑐𝑜𝑢𝑛𝑡 𝑖𝑠 2%
𝑃 = $ 500
𝑄 = 20
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365 12
𝑇𝑐 𝑄 ∗ = 20. + 100. + (365𝑋500)
12 2
365 20
𝑇𝑐 𝑄 = 20. + 100. + 365(0.98𝑥500)
20 2
Comparing the individual costs components for the two models, the ordering costs decreases
The reduction in the O.C will not offset the increase in the C.C but the 2% discount in
purchase price more than offsets the increased costs and the result is a saving of $ 3493.
Consider a hospital that buys a certain antibiotic from a large supplier. The drug can be
1-4999 2.75
5000-9999 2.6
The demand for the drug in the hospital is 50,000 units per year. There is an order cost of $50
per order and a holding cost of 20% of the cost of the item per unit per year. Determine the
𝐷 = 50000/𝑦𝑒𝑎𝑟
𝐶𝑜 = $50/𝑜𝑟𝑑𝑒𝑟
𝐶𝑐 = 0.2/𝑢𝑛𝑖𝑡/𝑦𝑒𝑎𝑟
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Steps
2 ∗ 50 ∗ 50000
𝑄1 = √ = 3163 𝑢𝑛𝑖𝑡𝑠.
0.5
2. Compare Q1* to the quantity required for the price break i.e. 10,000 and above; if Q* is
larger than this quantity the problem is solved; if less, the solution isn’t feasible and the
search continues.
In the above case 3163 is not feasible because it is less than 10000
3. Select the next higher item cost i.e. $2.6 and calculate the EOQ: Q2*
2 ∗ 50 ∗ 50000
𝑄2 = √ = 3100.86 𝑢𝑛𝑖𝑡𝑠
0.2𝑥2.6
4. Repeat step number 2 i.e. compare Q2 * to the range that is required for the equivalent
price; since Q2* is not within this range the solution is not feasible and the search
continues.
2 ∗ 50 ∗ 50000
𝑄3 = √ = 3015 𝑢𝑛𝑖𝑡𝑠
0.2𝑥2.75
Since Q3* is within the appropriate range of the price it’s a feasible solution.
6. Execute a cost comparison i.e. the total annual cost is computed for the feasible EOQ.
This cost is compared with the total annual cost for each of the minimum quantities for
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50000 3015
𝑇𝑐 (3015) = 50. + 0.55𝑥 + 50000𝑥2.75
3015 2
= 139158
50000 5000
𝑇𝑐 (5000) = 50. + 0.52𝑥 + 50000𝑥2.60
5000 2
= 131800
50000 10000
𝑇𝑐 (10000) = 50. + 0.5𝑥 + 50000𝑥2.50
10000 2
= 127750
Conclusion
The hospital should make orders of 10,000 and above because this minimizes the total inventory
costs.
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PRODUCTION LOT-SIZE MODEL
The retail model assumes that the entire replenishment order is received instantaneously.
However for the production model, the replenishment results from a production run which may
take a significant time to complete i.e. the production line output goes into the finished stock
inventory and the goods demanded are supplied from the inventory.
The basic production lot-size model assumes a zero re-order point and will not allow stock-outs.
Inventory Level Q
M Max Inventory
Average Inventory
O
T1 T2 Time
The total inventory cost is made up of set- up cost and holding costs.
Let Co represent the set up cost or production lot size run i.e. the set up cost component is
𝐷
𝑆𝑒𝑡 𝑢𝑝 𝑐𝑜𝑠𝑡𝑠 = 𝐶𝑜
𝑄
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If we let 𝐶𝑐 be the holding costs per unit per time period then the holding cost component of this
model can be defined similarly to the carrying cost component of the EOQ model
The average inventory for this model differs slightly from the EOQ model. It is computed by
1 1
𝑡 𝑚+ 𝑡2 𝑚
2 1
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑖𝑛𝑣𝑒𝑛𝑡𝑜𝑟𝑦 = 2
……………………………..*
𝑡1 +𝑡2
Let 𝑟1 be the number of units per time period resulting from the production process i.e. the rate at
Let 𝑟2 represent the number of units per time period demanded (equivalent is the D in the EOQ
model)
In a feasible model the production rate 𝑟1 must be greater than the demand rate 𝑟2 (𝑟1 > 𝑟2 );
otherwise production will not be able to keep up with the demand. Therefore immediately after
an order is placed in production, the inventory levels rises at a constant rate of (𝑟1 − 𝑟2 ) until the
𝑄
Since 𝑟1 is the production rate then 𝑡1 = 𝑟 which is the time period taken to produce the entire
1
order.
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The number of units demanded during the period 𝑡1 is given by
𝑟2 𝑡1
𝑄
𝐵𝑢𝑡, 𝑡1 =
𝑟1
𝑄
𝑇ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒 𝑑𝑒𝑚𝑎𝑛𝑑 = . 𝑟2
𝑟1
𝑄
𝑎𝑛𝑑 𝑚 = 𝑄 – 𝑟
𝑟1 2
𝑟2
𝑀 = 𝑄 (1 − )
𝑟1
Substituting 𝑚 in average equation (*) above and solving the average inventory =
1 𝑟 1 𝑟
𝑡1 {𝑄 (1 − 2 )} + 𝑡2 {𝑄 (1 − 2 )}
2 𝑟1 2 𝑟1
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐼𝑛𝑣𝑒𝑛𝑡𝑜𝑟𝑦 =
𝑡1 + 𝑡2
𝑄 𝑟2
𝐴. 𝐼 = (1 − )
2 𝑟1
𝑄 𝑟2
𝐻𝑜𝑙𝑑𝑖𝑛𝑔 𝐶𝑜𝑠𝑡 = 𝐶𝑐 𝑥 (1 − )
2 𝑟1
𝐷 𝑄 𝑟2
𝑀𝑖𝑛 𝑇𝑐 = 𝐶𝑜 . + 𝐶𝑐 . (1 − )
𝑄 2 𝑟1
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𝜕𝑇𝑐 𝐷 1 𝑟2
= −𝐶𝑜 2 + 𝐶𝑐 . {1 − } = 0
𝜕𝑄 𝑄 2 𝑟1
𝐷 𝐶𝑐 𝑟2
𝐶𝑜 = {1 − }
𝑄2 2 𝑟1
2𝐶𝑜 . 𝐷
𝑡ℎ𝑒𝑟𝑒𝑓𝑜𝑟𝑒 𝑄 ∗ = √ 𝑟
𝐶𝑐 {1 − 𝑟2 }
1
Example
A company has decided to begin manufacturing a spare part that it has previously been
purchasing from an outside vendor. The demand is 1000 unit/month. The set up cost per run is
Once a machine is running it can produce the spare parts at a rate of 2500/month. The company
The management would like to know the production lot size to run, how after production runs
should be made and the total costs associated with the recommended run size.
𝐶𝑜 = 20
𝐶𝑐 = 5 / 𝑢𝑛𝑖𝑡/ 𝑦𝑒𝑎𝑟
𝑟1 = 2500/ 𝑚𝑜𝑛𝑡ℎ
𝑟2 = 1000/ 𝑚𝑜𝑛𝑡ℎ
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2𝑥20𝑥12000
𝑄∗ = √ = 400
1000
5(1 −
2500
𝐷 12000
𝑁∗ = ∗
= = 30
𝑄 400
1 1
𝑡= ∗
= = 0.03
𝑁 30
𝑟2
𝑇𝐶 = √2𝐶0 𝐶𝑐 𝐷 {1 − }
𝑟1
= $1200.
For 𝑚
𝑟2
𝑚 = 𝑄 (1 − )
𝑟1
= 240.
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