1 IRWIN a Times Mirror Higher Education Group, Inc. company, 1996 Inventory Management CHAPTER 12
2IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
What is Inventory? Stock (or any resource) held for future use “Insurance” Policy/Buffer -- Just-in-Case Critical resource “Dead” resource The same as money Something most organizations have too much of!! The “root of all evil” - Japanese view
3IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Types of Demand
Independent (Master Production Schedule)– Bicycle
Dependent (Materials Requirements Plan)– Chain– Frame– Sprockets– Spokes
4IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Types of Inventory
Raw materials and purchased parts Work in process (WIP) and goods
in transit Finished goods Spare parts, tools, and supplies
5IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Functions of Inventory Satisfy anticipated demand Smooth production requirements Decouple operations Protect against stockouts/serve customers immediately Buy/produce economic lot sizes (cycle stock) Hedge against price increases Permit on-going operations
6IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Inventory Management
Primary Objectives– Maximize Customer Service, yet Minimize Costs– Replace Inventory with Information
With Mismanagement– Higher costs– Difficult to control– Hides production problems
7IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Requirements for Effective Inventory Management
A comprehensive strategic view– Committed– Systematic– Organizationwide– People-based
8IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Requirements for Effective Inventory Management
A system to keep track of inventory– Counting/Monitoring– Physical control
» Location, security, policies– Accountability
» Annual inventory vs. cycle counting
11IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Requirements for Effective Inventory Management (cont.)
Demand forecasts/market intelligence– Past history, Point of Sale (POS) Information
Knowledge of lead times & variability– Purchasing, fabrication, assembly
12IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Requirements for Effective Inventory Management (cont.)
Estimates of pertinent costs– Holding/carrying, ordering, shortage,
expediting (Details later)
13IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Requirements for Effective Inventory Management (cont.)
A priority classification system– A-B-C system
14IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Divides on-hand inventory into 3 classes– A, B , C
Basis is usually annual $ volume– $ volume = Annual demand x Unit cost
Control policies based on ABC analysis
ABC Analysis
15IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
0
20
40
60
80
100
0 50 100% of Inventory Items% of Inventory Items
% Annual $ Usage% Annual $ Usage
AABB CC
Class % $ Vol % ItemsA 80 15B 15 30C 5 55
Classifying Items as ABC
16IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Physically counting a sample of total inventory on a regular basis
Used often with ABC classification– A items counted most often (e.g., daily)
Cycle Counting
17IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Requirements for Effective Inventory Management
A computer system?– Technology is a tool, not salvation!!! --
Avoiding GIGO, GASL and other maladies Replacement of inventory with
information!!– Believe and use the data in the system
18IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Fundamental Analysis & Replenishment Issues
How much to order (quantity)– EOQ model
When to place an order (timing)– Reorder point model
19IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Holding/Carrying Costs
Proportional to Order Size Measured in $ per unit per year
– Obsolescence– Insurance– Extra staffing– Interest/Cost of Capital– Pilferage– Damage– Warehousing/Space
20IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Ordering Costs
Proportional to Number of Orders Measured in $ per order
– Supplies/Forms– Inspection– Order processing– Clerical support– Expediting
21IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
How Much to Order - EOQ model
The “annual demand pie” Equal sized pieces - fixed order quantity (Q) The basic tradeoff-cost minimization The inventory cycle The optimal order quantity
22IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
When to Reorder with EOQ Ordering
Reorder Point - When the quantity on hand of an item drops to this amount, the item is reordered
ROP is a function of: Safety Stock - Stock that is held in excess of expected
demand due to variable demand rate and/or lead time. Service Level - Probability that demand will not
exceed supply during lead time.
23IRWIN
a Times Mirror Higher Education Group, Inc. company, 1996
Safety Stock
LT Time
Expected demandduring lead time
Maximum probable demandduring lead time
ROP
Qua
ntity
Safety stock