INVENTORY MANAGEMENT INVENTORY MANAGEMENT
Mar 29, 2015
INVENTORY INVENTORY MANAGEMENTMANAGEMENT
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of Inventory management It is the sum of value of raw materials, fuels and
lubricants, spare parts, maintenance consumables, semi processed and finished goods.
Inventories1.Production Inventories
2.MRO Inventories
3.In-Process inventories
4.Finished goods inventories.
Inventory Analysis Inventory planning and subsequent control of an
inventory is accomplished on the basis of knowledge about each of the individual items and the finished products of which each is a part.
Inventory Catalogue1.it serves as a medium of communication
2. an inventory catalogue accrues to the inventory control operation it self.
Functions of inventories.
It makes possible smooth and efficient operation of a manufacturing organization by decoupling individual segments of total operation.
1.Purchased part inventories
2.Inventories of parts and components
3.Finished goods inventories
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Inventory Management in India
Inventory may be defined as sum of value of raw materials, fuels and lubricants, spare parts, maintenance consumables, semi possessed materials & finished goods at any given point of time.
These resources are called idle resources since they are idle they are kept in the stores.
These resources are maintained for operational smoothness.
The size of inventory depends on internal lead time, suppliers lead time, vendors relation and availability of raw materials.
Finished goods inventory are maintained to ensure free flowing supply of goods to customers.
Two factors which affect inventories are:-
1. Accuracy & detail of final forecast.
2. Availability of storage space.
Norms for inventory
1. The department set up monetary limits for investment in inventories.
2. They have to allocate the investments to various items and ensure smooth operations of the company.
3. While setting the norms involvement of people making the norms is desirable.
4. Departments like finance, production are included.
Peculiarities in India
It operates in sellers market for purchase of goods.
Indian industry tends to stress a lot on machine utilization.
In India, inventory control technique do not run under “ free availability” of goods
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Classification of Inventories
Production InventoryMRO Inventory (Maintenance Repair
Operating Supplies)In-process InventoryFinished Goods Inventory
Forces Creating Various Types of Inventory
Creating Forces Type of Inventory
Uncertainties
Batch / Lot Size Economics
Time Transportation
Time-processing
Seasonality
Varying activity rates
Safety Stocks
Cycle Stocks
In-transit
Work in Process
Seasonal Stocks
Decoupling Stocks
Three Components of Inventory Management
Forecasting: How much do we need?
when will we need it?
Replenishment: How much should we order? When should we order?
Inventory control: How much do we have on hand? How much do we have on order? How much have we sold?
Dependent and Independent Demand
Costs relevant for Inventory Decision
• Holding Costs : Capital costs, inventory service costs, storage space and risk costs.
• Shortage Costs: Penalty for not having inventory available when required.
• Acquisition Costs: Cost to order and acquire inventory.
• Control System Costs: Cost of administrating systems needed to manage inventory levels.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
COSTS ASSOCIATED WITH INVENTORIES
CARRYING COSTS
ACQUISITION COSTS
CARRYING COSTS
• Carrying material in inventory is expensive.
• The annual cost of carrying a production inventory averaged approximately 25% of the value of the inventory.
CARRYING COSTS
1 Opportunity cost of invested funds 12 – 20 %
2 Insurance costs 2 – 4 %
3 Property taxes 1 – 3 %
4 Storage costs 1 - 3 %
5 Obsolescence and deterioration 4 – 10 %
Total carrying costs 20 – 40 %
0
AC
CC
Annual cos t s
Inventory level (or order/delivery quantity)
Relationship of inventory-related costs to inventory level (AC = acquisition costs; CC = carrying costs)
(carrying cost / year) = (average inventory value) x (inv. Carrying cost as a % of inv. value)
(carrying cost / year) = (average inventory in units) x (material unit cost) x (inv. Carrying cost as a % of inv. value)
CC = Q x C x I2
Where CC = carrying cost/yr for the material in question Q = order or delivery quantity for the material, in units C = delivery unit cost of the material I = inventory carrying cost for the material, expressed as a % of the inventory value
Acquisition costsAcquisition costs
1. A certain portion of wages and operating expenses of such departments as purchase and supply, production control, receiving etc.
2. The cost of supplies such as engineering drawings, envelopes, stationery, and forms of purchasing etc.
3. The cost of services such as computer time, telephone, fax etc.
It can be calculated as follows:(acquisition cost/year) = (no of orders
placed/yr) x (acquisition cost per order)
AC = U/Q x A
Where, AC = acquisition cost /year for the material in question U = expected annual usage of the material Q = order or delivery quantity for the material A = acquisition cost/order or per delivery for the material.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Sr No. Type of Control Criteria Application
1) ABC analysis Annual Consumption value of To control inventory
the item of raw material
& WIP inventory
2) XYZ analysis Inventory value of items in To review the
stores actual inventories
their uses, etc. at
scheduled intervals.
3) VED analysis Criticality of the item To determine the
stocking level of
spare parts for
machines &
equipments.4) FSN analysis Consumption pattern of the To control
items obsolescence.
Sr No. Type of Control Criteria Application
5) HML analysis Unit price of the item To control the
purchases & to
develop vendors.
6) SDE analysis Purchasing problem Lead time analysis
in regard to availability & purchasing
strategies.7) SOS analysis Nature of supplies & Procurement &
seasonality holding stratergy
for seasonal term.8) GOLF analysis Source of supply of Procurement
material strategy.
Advantages of selective control system
Helps the material manager to exercise selective control and focus attention only on few vital items.
Able to control inventories and thereby achieve management objectives.
Results in proper inventory analysis & obsolete stocks are pinpointed.
Results in reduced administrative costs & improve inventory turnover.
Powerful approach in the direction of cost reduction as it is helps to control items with selective approach.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
ABC AnalysisABC Analysis
What is ABC analysis? ABC analysis is a basic analytical management
tool which enables top management to place the effort where the results will be greatest.
The techniques tries to analyze the distribution of any characteristic by money value of importance in order to determine it’s priority.
ADVANTAGES OF ABC ANALYSIS
This approach helps the material manager to exercise selective control and focus his attention only on few items when he is confronted with lakhs of stores items.
By concentrating on ‘A’ class items, the material manager is able to control inventories and is able to show ‘Visible’ results in a short span of life.
By controlling the ‘A’ items, and doing a proper inventory analysis, obsolete stocks are automatically pinpointed.
MECHANICS OF ABCABC ANALYSIS
The mechanics of classifying the items into ‘A’, ‘B’ and ‘C’ categories is described here:
1. CALCULATE
2. SORT
3. PREPARE A LIST
4. COMPUTE A RUNNING TOTAL
5. COMPUTE AND PRINT
100
90
75
010 30 100
Cumulative % number
CCuummuullaat t iivve e
%% vvaalluuee
A B C
Basic principles of ABC analysis are:
1. The analysis does not depend upon the unit cost of the items but only on its annual consumption value.
2. It does not depend on the importance of the item.
3. The limits of ABC categorization are not uniform but will depend upon the size of the undertaking, its inventory as well as the number of items controlled.
PURPOSE OF ABC ABC ANALYSIS
A A items: High consumption value1. Very strict control
2. No safety stocks
3. Frequent ordering or weekly deliveries
4. Weekly control statements
5. Maximum follow-up and expediting
6. Rigorous value analysis
7. As many sources as possible for each item
8. Accurate forecasts in material planning
9. Minimisation of waste, obsolete and surplus
10. Individual postings
11. Central purchasing and storage
12. Maximum efforts to reduce lead time
13. Must be handled by senior officers
BB items: moderate value1. Moderate control
2. Low safety stocks
3. Once in three months
4. Monthly control report
5. Periodic follow-up
6. Moderate value analysis
7. Two or more reliable sources
8. Estimates based on past data on present plans
9. Quarterly control over surplus and obsolete items
10. Small group postings
11. Combination purchasing
12. Moderate
13. Can be handled by middle management
C C items : low consumption value1. Loose control
2. High safety stock
3. Bulk ordering once in six months
4. Quarterly control reports
5. Follow-up and expediting in exceptional cases
6. Minimum value analysis
7. Two reliable sources for each other item
8. Rough estimates for planning
9. Annual review over surplus and obsolete material
10. Group positioning
11. Decentralized purchasing
12. Minimum clerical efforts
13. Can be fully delegated
Objectives of ABCABC analysis
Item noItem no Annual consumption Annual consumption value (Rs)value (Rs)
No of ordersNo of orders Value per Value per orderorder
Average Average inventoryinventory
11
22
33
60,00060,000
4,0004,000
1,0001,000
44
44
44
15,00015,000
1,0001,000
250250
7,5007,500
500500
125125
Total inventoryTotal inventory Rs 8,125Rs 8,125
Exhibit 1Exhibit 1
Exhibit 2Exhibit 2
Item noItem no Annual consumption Annual consumption value (Rs)value (Rs)
No of ordersNo of orders Value per Value per orderorder
Average Average inventoryinventory
11
22
33
60,00060,000
4,0004,000
1,0001,000
88
33
11
75007500
133133
10001000
37503750
667667
500500
Total inventoryTotal inventory Rs 4,917Rs 4,917
Limitations of ABC analysis
ABC analysis is based on grading the items according to the importance of the performance of an item, that is V.E.D.- Vital Essential and Desirable- analysis. Some times, through negligible in monetary value, may be vital for running the plant, and constant attention is needed.
Music – 3D Analysis
Consumption ValueDelivery TimeCriticality
High Level Consumption
Low Level Consumption
Long Lead Time
HLC&LLT
critical
HLC&LLT
non-critical
LLC&LLT
critical
LLC&LLT
non-critical
Short Lead Time
HLC&SLT
critical
HLC&SLT
non-critical
LLC&SLT
critical
LLC&SLT
non-critical
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
ECONOMIC ORDERING QUANTITY(EOQ)
INTRODUCTION
• EOQ can be defined as that quantity which should be ordered during the lead time so that it becomes economic to order and the inventory carrying cost becomes minimum.• When ordering quantity is less than EOQ, ordering cost will increase.• When ordering quantity is more than EOQ, inventory carrying cost will increase • Thus, EOQ refers to the quantity in which the ordering cost is equal to the holding cost (Inventory carrying cost)
GRAPHICAL DERIVATION OF EOQ
Y TC
HERE: EOQ = Economic ordering quantity
TC = Total Cost
COST ICC ICC = Inventory Carrying Cost
OC = Ordering Cost
OC
O EOQ X
ORDER QUANTITY
DERIVATION OF EOQ FORMULAE Annual Ordering Cost = Annual Inventory Carrying Cost A x Co = 0 + Q x i x Cc Q 2
Solving for ‘Q’
Q x Q = 2 x A x Co i x Cc
Q = 2 x A x Co i x Cc
HERE : A = Annual Demand ; Co = Cost of ordering ; Q = EOQ ; i = Cost per unit ; Cc = Cost of carrying or ICC
PROBLEMS ON EOQ
1. Annual Demand = 20,000 units
Ordering Cost = Rs. 100
ICC = 20 %
Unit Price = Rs. 20
A. EOQ = 2 x A x Co
I x Cc
EOQ = 2 x 20,000 x 100
20 x 0.20
EOQ = 1,000 units
2. In a leading biscuit manufacturing organization, the annual demand for corrugated boxes is 20,000. The cost of placing an order is Rs. 100 and the inventory carrying cost is 20 per cent. The price per box is Rs. 10. The supplier offers 1 per cent discount if 4,000 corrugated boxes or more are purchased and 3.5% discount if 10,000 units or more are purchased. What should be the ordering quantity and would you accept the discount?
A. EOQ = 2 x A x Co
I x Cc
EOQ = 2 x 20,000 x 100
10 x 0.20
EOQ = 1,414 units
Number of orders placed in the year = 20,000
1414 = 14.14 orders1 ) 1% for 4,000 Savings - Inventory Carrying Cost (ICC) Savings = Discount + Cost of ordering Discount = 1 x 20,000 x 10 100 = Rs. 2,000 Cost of ordering = [14.14 – (20,000/4,000)] x 100 = Rs. 914 Savings = Rs. (2,000 + 914) = Rs. 2,914 Inventory Carrying Cost (ICC) = ( 4,000- 1,414/2) x 10 x0.20 = Rs. 2,586 Rs. (2,914 - 2,586) = Rs. 328 Accept the offer
2) 3.5% for 10,000
Savings - Inventory Carrying Cost (ICC)
Savings = Discount + Cost of ordering
Discount = 3.5 x 20,000 x 10
100
= Rs. 8,000
Cost of ordering = [14.14 – (20,000/10,000)] x 100
= Rs. 1214
Savings = Rs. (7,000 + 1214)
= Rs. 8,214
Inventory Carrying Cost (ICC) = ( 10,000- 1,414/2) x 10 x0.20
= Rs. 8,586
Rs. (8,214 - 8,586) = - (Rs. 372)
Reject the offer
LIMITATIONS OF EOQ
Not suitable when annual demand fluctuates widely.
Not suitable when cost per unit fluctuates widely.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Materials Requirement Planning (MRP)
MRP is a computer based control system that determines how much of each material, any inventory item with a unique part / number, should be purchased or produced in each time period to support the master production schedule (MPS)
- ( Newman, 1994)
MRP is, by necessity, a computer based system which is designed to:
1. Release production and purchase orders.
2. Ensure availability of materials, components and products.
3. Maintain minimum levels.
Major objectives of MRP are:
1. Improve customer service.
2. Reduce inventory costs.
3. Enhancing operating efficiency.
Elements of MRPElements of MRP
Orders/ forecast of service parts
Inventory status file
MasterProduction
schedule
Bill ofMaterial
file
MRPsystem
Inventory Transaction
data
Changes to planOrders
Planned orderschedule
Planning reports
Performance reports
Exception reportsMRP computer programme
inputs outputs
Primary outputs
Secondary outputs
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.
P - SYSTEM
• Fixed Order Period System• Not Suitable for ‘A’ Class Items• Extremely Useful for ‘B’ & ‘C’ Class Items• Desired Inventory Level = Buffer stock +
Safety stock + Reserve stock
Q- SYSTEM
• Fixed Order Quantity System• Re-order point determined by Buffer stock,
Reserve stock & Safety stock • Suitable for ‘A’ Class Items• Requires continuous review of inventory
Buffer Stock: Average demand during average lead-time
Reserve Stock: Variations in demand during average lead time are known as reserve stock depend on service level
Safety Stock: Average demand obtained through multiplying average demand for maximum delay & probability of delay
Annual demand = 20,000 units; Standard deviation of demand per week = 50 units; Price
per unit = Rs.10; Ordering cost = Rs.100; Inventory carrying cost = 20%; Average lead time = 4 weeks; Maximum delay =3 weeks; Probability of delay = 0.31; Service level =
95%(1.64)
Solution: ‘Q’ System
Order quantity = EOQ
s*Cc = 2 * 20,000 *100 10 * 0.20 = 1414 units
Re-order point = Buffer Stock + Reserve Stock + Safety StockBuffer Stock = 20000 * 4 = 1540 units 52Reserve Stock = 4*50*100 = 164 units
2*M*Co
Safety Stock = 20,000 *3 *0.31 52 = 358 units
Re-order point = 1540+164+358 = 2062 units
Solution: ‘P’ SystemReview period = EOQ *52 weeks M = 1414 * 52 weeks 20000 = 3.7 weeks
Buffer Stock = 20,000 * 8 = 3080 units 52
Reserve Stock = 8 *50 *1.64 = 230 units
Safety Stock = 20,000 *3 * 0.31 = 358 units 52
Desired Inventory Level = 3080 + 230 + 358 = 3668 units
Definition of inventories, inventory analysis and inventory catalog. Inventory management in India. Classification of inventories, forces creating various hypes of inventories, safety stock. Cost associated with inventories. Types of selective inventory control and advantages of selective control. ABC analysis. EOQ. MRP. P & Q systems.