College of Business Administration

Cal State San Marcos

Production & Operations Management

HTM 305

Dr. M. Oskoorouchi

Summer 2006

CHAPTER

11

Inventory

Management

Types of Inventories

Raw materials & purchased parts

Partially completed goods called work in progress

Finished-goods inventories

(manufacturing firms) or merchandise (retail stores)

Functions of Inventory

To meet anticipated demand

To smooth production requirements

To protect against stock-outs

To take advantage of order cycles

To hedge against price increases

To take advantage of quantity discounts

A system to keep track of inventory

A reliable forecast of demand

Knowledge of lead times

Reasonable estimates of

Holding costs

Ordering costs

Shortage costs

Effective Inventory Management

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

Ordering costs: costs of ordering and

receiving inventory

Shortage costs: costs when demand exceeds

supply

Key Inventory Terms

Inventory Counting Systems

Periodic System

Physical count of items made at periodic

intervals

Perpetual Inventory System System that keeps track

of removals from inventory

continuously, thus

monitoring

current levels of

each item

Inventory Counting Systems

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

0

214800 232087768

ABC Classification System

Classifying inventory according to some measure of importance and allocating control efforts accordingly.

A - very important

B - mod. important

C - least important Annual $ value

of items

A

B

C

High

Low

Few Many Number of Items

Economic order quantity model

Economic production quantity model

Quantity discount model

Economic Order Quantity Models

Only one product is involved

Annual demand requirements known

Demand is even throughout the year

Lead time does not vary

Each order is received in a single delivery

There are no quantity discounts

Assumptions of EOQ Model

The Inventory Cycle

Profile of Inventory Level Over Time

Quantity

on hand

Q

Receive

order

Place

order Receive

order Place

order

Receive

order

Lead time

Reorder

point

Usage

rate

Time

Order frequency

Annual carrying cost

Annual carrying cost =

(average number of inventory)*(holding cost/unit/year)

Average number of inventory = (Q+0)/2 = Q/2

Annual carrying cost = (Q/2)H,

Where

Q = Order quantity in units

H = Holding cost /unit/year

Total Cost

Annual carrying cost

Annual ordering cost

Total cost = +

Q 2

H D Q

S TC = +

Cost Minimization Goal

Order Quantity

(Q)

The Total-Cost Curve is U-Shaped

Ordering Costs

QO

An

nu

al C

ost

(optimal order quantity)

TCQ

HD

QS

2

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.

Q = 2DS

H =

2(Annual Demand )(Order or Setup Cost )

Annual Holding CostOPT

Example

A toy manufacturer uses approximately 32,000

silicon chips annually. The chips are used at a

steady rate during the 240 days a year that the

plant operates. Annual holding cost is $3 per chip,

and ordering cost is $120. Determine

The optimal order quantity.

Holding cost, ordering cost, and the total cost.

The number of workdays in an order cycle.

Problem

PM assembles security monitors. It purchases

3,600 black-and-white cathode ray tubes a year

at $65 each. Ordering costs are $31, and annual

carrying costs are 20% of the purchase price.

Compute

The optimal quantity

the total annual cost of ordering and carrying the

inventory.

Problem

A large bakery buys flour in 25-pound bags. The bakery uses an average of 4,860 bags a year. Preparing an order and receiving a shipment of flour involves a cost of $10 per order. Annual carrying costs are $75 per bag

Determine the economic order quantity.

What is the average number of bags on hand.

How many orders per year will there be?

Compute the total cost of ordering and carrying flour.

If ordering costs were to increase in $1 per order, how much would that affect the minimum total annual cost?

Production done in batches or lots

Capacity to produce a part exceeds the parts

usage or demand rate

Assumptions of EPQ are similar to EOQ

except orders are received incrementally

during production

Economic Production Quantity (EPQ)

Only one item is involved

Annual demand is known

Usage rate is constant

Usage occurs continually

Production rate is constant

Lead time does not vary

No quantity discounts

Economic Production Quantity Assumptions

EPQ Model

Economic Run Size

QDS

H

p

p u0

2

Example

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 day per year. Determine the

Optimal run size

Minimum total annual cost for carrying and setup

Cycle time for the optimal run

Run time.

Problem

The Dine Corporation is both a producer and a user of brass couplings. The firm operates 220 days a year and uses the couplings at a steady rate of 50 per day. Couplings can be produced at a rate of 200 per day. Annual storage cost is $2 per coupling, and machine setup cost is $70 per run.

Determine the economic run quantity

Approximately how many runs per year will there be?

Compute the maximum inventory level.

Determine the length of the pure consumption portion of the cycle.

Problem

The Friendly Sausage Factory (FSF) can produce hot dogs

at a rate of 5,000 per day. FSF supplies hot dogs to local

restaurants at a steady rate of 250 per day. The cost to

prepare the equipment for producing hot dogs is $66.

annual holding costs are 45 cents per hot dog. The factory

operates 300 days a year. Find

The optimal run size.

The number of runs per year.

The maximum inventory level.

The length of run.

Review: EOQ Model

Cost Minimization Goal

Order Quantity

(Q)

The Total-Cost Curve is U-Shaped

Ordering Costs

QO

An

nu

al C

ost

(optimal order quantity)

TCQ

HD

QS

2

Holding Costs

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.

Q = 2DS

H =

2(Annual Demand )(Order or Setup Cost )

Annual Holding CostOPT

Total Cost

Annual carrying cost

Annual ordering cost

Total cost = +

Q 2

H D Q

S TC = +

Total Costs with Purchasing Cost

Annual carrying cost

Purchasing cost TC = +

Q 2

H D Q

S TC = +

+ Annual ordering cost

PD +

EOQ models with constant purchase price:

Total Costs with PD

Co

st

EOQ

TC with PD

TC without PD

PD

0 Quantity

Adding Purchasing cost

doesnt change EOQ

Total Costs with quantity discount

Order

quantity

Unit Price

1 to 44 $2.00

45 to 69 1.70

70 or more 1.40

Example: Constant Carrying Costs

A mail-order house uses 18,000 boxes a year. Carrying costs

are 60 cents per box a year, and ordering costs are $96. The

following price schedule applies:

Determine the optimal order quantity.

Determine the number of orders per year.

Number of boxes Price per box

1,000 to 1,999 $1.25

2,000 to 4,999 1.20

5,000 to 9,999 1.15

10,000 or more 1.10

2,400 5,000 10,000

Quantity

TC

Lowest TC

Total Costs with Purchase discount

Steps for total Cost with Constant Carrying Costs

Compute the common minimum point.

Only one of the unit prices will have the minimum point in its feasible range since the ranges do not overlap. Identify that range.

If the feasible minimum point is on the lowest price range, that is the optimal order quantity.

Otherwise, compute the total cost for the minimum point and for the price breaks of all lower unit costs. Compare the total costs; the quantity (minimum point or price break) that yields the lowest total cost is the optimal order quantity.

Problem: Constant Carrying Costs

The maintenance department of a large hospital uses about 816 cases of liquid cleanser annually. Ordering costs are $12, carrying costs are $4 per case a year, and the new price schedule indicates that orders of less than 50 cases will cost $20 per case, 50 to 79 cases will cost $18 per case, 80 to 99 cases will cost $17 per case, and larger orders will cost $16 per case.

Determine the optimal order quantity and the total cost.

Problem: Constant Carrying Costs

A jewelry firm buys semiprecious stone to make bracelets

and rings. The supplier quotes a price of $8 per stone for

quantities of 600 stones or more, $9 per stone for orders

of 400 to 599 stones, and $10 per stone for lesser

quantities. The jewelry firm operates 200 days per year.

Usage rate is 25 stones per day, and ordering costs are

$48.

If carrying costs are $2 per day for each stone, find the

order quantity that will minimize total annual cost.

Total Costs with quantity discount

There are two general cases of the model:

Carrying costs are constant (for example, $2 per

unit)

Carrying costs are stated as a percentage of

purchase price (for example, 20% of purchase

price)

Problem: variable Carrying Costs

A jewelry firm buys semiprecious stone to make bracelets and rings. The supplier quotes a price of $8 per stone for quantities of 600 stones or more, $9 per stone for orders of 400 to 599 stones, and $10 per stone for lesser quantities. The jewelry firm operates 200 days per year. Usage rate is 25 stones per day, and ordering costs are $48.

If annual carrying costs are 30% of unit cost, what is the optimal order size?

Steps for total Cost with variable Carrying Costs

Beginning with the lowest unit price, compute the minimum points for each price range until you find a feasible minimum point (i.e., until a minimum point falls in the quantity range for its price).

If the minimum point for the lowest unit price is feasible, it is the optimal order quantity. If the minimum point is not feasible in the lowest price range, compare the total cost at the price break for all lower prices with the total cost of the feasible minimum point. The quantity which yields the lowest total cost is the optimum.

Problem: variable Carrying Costs

A manufacturer of exercise equipments purchases the pulley

section of the equipment from a supplier who lists these prices:

less than 1,000, $5 each; 1,000 to 3,999, $4.95 each; 4,000 to

5,999, $4.90 each; and 6,000 or more, $4.85 each. Ordering

costs are $50, annual carrying costs per unit are 40% of

purchase cost, and annual usage is 4,900 pulleys.

Determine an order quantity that will minimize total cost.

Problem: variable Carrying Costs

495 497 500 503 1,000 4,000 6,000

Quantity

TC

When to Reorder with EOQ Ordering

A simple case:

Demand is constant

Lead time is constant

ROP = d * LT

Example: Demand is 20 items per day and lead time is one week. What is the reorder point (ROP)?

When to Reorder with EOQ Ordering

Reorder Point - When the quantity on hand of an item drops to this amount, the item is reordered

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.

Determinants of the Reorder Point

The rate of demand (based on a forecast)

The lead time

Demand and/or lead time variability

Stockout risk (safety stock)

ROP = Expected demand during lead time +

safety stocks

Safety Stock

LT Time

Expected demand

during lead time

Maximum probable demand

during lead time

ROP

Qu

an

tity

Safety stock Safety stock reduces risk of

stockout during lead time

Reorder Point

ROP

Risk of

a stockout

Service level

Probability of

no stockout

Expected

demand Safety

stock

0 z

Quantity

z-scale

The ROP based on a normal

Distribution of lead time demand

Reorder Point

ROP = Expected demand during lead time + safety stocks

We discuss several models:

An estimate of expected demand during lead time and its standard deviation are available.

Data on lead time demand is not available: we consider three cases:

Demand is variable, lead time is constant

Lead time is variable, demand is constant

Both demand and lead time are variable

ROP for model 1

An estimate of expected demand during lead

time and its standard deviation are available

Expected demand

during lead timedLTROP z

Example

Given this information:

Expected demand during lead time = 300 units

Standard deviation of demand during lead time = 30 units

Determine each of the following, assuming that lead time demand is distributed normally:

The ROP that will provide a 5% risk of stockout during lead time.

The ROP that will provide a 1% risk of stockout during lead time.

The safety stock needed to attain a 1% risk of stockout during lead time.

Cumulative Distribution Function of the Standard Normal Distribution

Example: If Z is standard Normal random variable, then F(1.00) = P(Z 1.00) = .8413

z 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09

-3.0 0.0013 0.0013 0.0013 0.0012 0.0012 0.0011 0.0011 0.0011 0.0010 0.0010

-2.9 0.0019 0.0018 0.0018 0.0017 0.0016 0.0016 0.0015 0.0015 0.0014 0.0014

-2.8 0.0026 0.0025 0.0024 0.0023 0.0023 0.0022 0.0021 0.0021 0.0020 0.0019

-2.7 0.0035 0.0034 0.0033 0.0032 0.0031 0.0030 0.0029 0.0028 0.0027 0.0026

-2.6 0.0047 0.0045 0.0044 0.0043 0.0041 0.0040 0.0039 0.0038 0.0037 0.0036

-2.5 0.0062 0.0060 0.0059 0.0057 0.0055 0.0054 0.0052 0.0051 0.0049 0.0048

-2.4 0.0082 0.0080 0.0078 0.0075 0.0073 0.0071 0.0069 0.0068 0.0066 0.0064

-2.3 0.0107 0.0104 0.0102 0.0099 0.0096 0.0094 0.0091 0.0089 0.0087 0.0084

-2.2 0.0139 0.0136 0.0132 0.0129 0.0125 0.0122 0.0119 0.0116 0.0113 0.0110

-2.1 0.0179 0.0174 0.0170 0.0166 0.0162 0.0158 0.0154 0.0150 0.0146 0.0143

-2.0 0.0228 0.0222 0.0217 0.0212 0.0207 0.0202 0.0197 0.0192 0.0188 0.0183

-1.9 0.0287 0.0281 0.0274 0.0268 0.0262 0.0256 0.0250 0.0244 0.0239 0.0233

-1.8 0.0359 0.0351 0.0344 0.0336 0.0329 0.0322 0.0314 0.0307 0.0301 0.0294

-1.7 0.0446 0.0436 0.0427 0.0418 0.0409 0.0401 0.0392 0.0384 0.0375 0.0367

-1.6 0.0548 0.0537 0.0526 0.0516 0.0505 0.0495 0.0485 0.0475 0.0465 0.0455

-1.5 0.0668 0.0655 0.0643 0.0630 0.0618 0.0606 0.0594 0.0582 0.0571 0.0559

-1.4 0.0808 0.0793 0.0778 0.0764 0.0749 0.0735 0.0721 0.0708 0.0694 0.0681

-1.3 0.0968 0.0951 0.0934 0.0918 0.0901 0.0885 0.0869 0.0853 0.0838 0.0823

-1.2 0.1151 0.1131 0.1112 0.1093 0.1075 0.1056 0.1038 0.1020 0.1003 0.0985

-1.1 0.1357 0.1335 0.1314 0.1292 0.1271 0.1251 0.1230 0.1210 0.1190 0.1170

-1.0 0.1587 0.1562 0.1539 0.1515 0.1492 0.1469 0.1446 0.1423 0.1401 0.1379

-0.9 0.1841 0.1814 0.1788 0.1762 0.1736 0.1711 0.1685 0.1660 0.1635 0.1611

-0.8 0.2119 0.2090 0.2061 0.2033 0.2005 0.1977 0.1949 0.1922 0.1894 0.1867

-0.7 0.2420 0.2389 0.2358 0.2327 0.2296 0.2266 0.2236 0.2206 0.2177 0.2148

-0.6 0.2743 0.2709 0.2676 0.2643 0.2611 0.2578 0.2546 0.2514 0.2483 0.2451

-0.5 0.3085 0.3050 0.3015 0.2981 0.2946 0.2912 0.2877 0.2843 0.2810 0.2776

-0.4 0.3446 0.3409 0.3372 0.3336 0.3300 0.3264 0.3228 0.3192 0.3156 0.3121

-0.3 0.3821 0.3783 0.3745 0.3707 0.3669 0.3632 0.3594 0.3557 0.3520 0.3483

-0.2 0.4207 0.4168 0.4129 0.4090 0.4052 0.4013 0.3974 0.3936 0.3897 0.3859

-0.1 0.4602 0.4562 0.4522 0.4483 0.4443 0.4404 0.4364 0.4325 0.4286 0.4247

0.0 0.5000 0.4960 0.4920 0.4880 0.4840 0.4801 0.4761 0.4721 0.4681 0.4641

z 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09

0.0 0.5000 0.5040 0.5080 0.5120 0.5160 0.5199 0.5239 0.5279 0.5319 0.5359

0.1 0.5398 0.5438 0.5478 0.5517 0.5557 0.5596 0.5636 0.5675 0.5714 0.5753

0.2 0.5793 0.5832 0.5871 0.5910 0.5948 0.5987 0.6026 0.6064 0.6103 0.6141

0.3 0.6179 0.6217 0.6255 0.6293 0.6331 0.6368 0.6406 0.6443 0.6480 0.6517

0.4 0.6554 0.6591 0.6628 0.6664 0.6700 0.6736 0.6772 0.6808 0.6844 0.6879

0.5 0.6915 0.6950 0.6985 0.7019 0.7054 0.7088 0.7123 0.7157 0.7190 0.7224

0.6 0.7257 0.7291 0.7324 0.7357 0.7389 0.7422 0.7454 0.7486 0.7517 0.7549

0.7 0.7580 0.7611 0.7642 0.7673 0.7704 0.7734 0.7764 0.7794 0.7823 0.7852

0.8 0.7881 0.7910 0.7939 0.7967 0.7995 0.8023 0.8051 0.8078 0.8106 0.8133

0.9 0.8159 0.8186 0.8212 0.8238 0.8264 0.8289 0.8315 0.8340 0.8365 0.8389

1.0 0.8413 0.8438 0.8461 0.8485 0.8508 0.8531 0.8554 0.8577 0.8599 0.8621

1.1 0.8643 0.8665 0.8686 0.8708 0.8729 0.8749 0.8770 0.8790 0.8810 0.8830

1.2 0.8849 0.8869 0.8888 0.8907 0.8925 0.8944 0.8962 0.8980 0.8997 0.9015

1.3 0.9032 0.9049 0.9066 0.9082 0.9099 0.9115 0.9131 0.9147 0.9162 0.9177

1.4 0.9192 0.9207 0.9222 0.9236 0.9251 0.9265 0.9279 0.9292 0.9306 0.9319

1.5 0.9332 0.9345 0.9357 0.9370 0.9382 0.9394 0.9406 0.9418 0.9429 0.9441

1.6 0.9452 0.9463 0.9474 0.9484 0.9495 0.9505 0.9515 0.9525 0.9535 0.9545

1.7 0.9554 0.9564 0.9573 0.9582 0.9591 0.9599 0.9608 0.9616 0.9625 0.9633

1.8 0.9641 0.9649 0.9656 0.9664 0.9671 0.9678 0.9686 0.9693 0.9699 0.9706

1.9 0.9713 0.9719 0.9726 0.9732 0.9738 0.9744 0.9750 0.9756 0.9761 0.9767

2.0 0.9772 0.9778 0.9783 0.9788 0.9793 0.9798 0.9803 0.9808 0.9812 0.9817

2.1 0.9821 0.9826 0.9830 0.9834 0.9838 0.9842 0.9846 0.9850 0.9854 0.9857

2.2 0.9861 0.9864 0.9868 0.9871 0.9875 0.9878 0.9881 0.9884 0.9887 0.9890

2.3 0.9893 0.9896 0.9898 0.9901 0.9904 0.9906 0.9909 0.9911 0.9913 0.9916

2.4 0.9918 0.9920 0.9922 0.9925 0.9927 0.9929 0.9931 0.9932 0.9934 0.9936

2.5 0.9938 0.9940 0.9941 0.9943 0.9945 0.9946 0.9948 0.9949 0.9951 0.9952

2.6 0.9953 0.9955 0.9956 0.9957 0.9959 0.9960 0.9961 0.9962 0.9963 0.9964

2.7 0.9965 0.9966 0.9967 0.9968 0.9969 0.9970 0.9971 0.9972 0.9973 0.9974

2.8 0.9974 0.9975 0.9976 0.9977 0.9977 0.9978 0.9979 0.9979 0.9980 0.9981

2.9 0.9981 0.9982 0.9982 0.9983 0.9984 0.9984 0.9985 0.9985 0.9986 0.9986

3.0 0.9987 0.9987 0.9987 0.9988 0.9988 0.9989 0.9989 0.9989 0.9990 0.9990

Problem

Suppose that the manager of a construction supply house determine from historical records that demand for sand during lead time obeys a normal distribution with mean 35 tons and standard deviation of 2.5 tons.

What value of z is appropriate if the manager is willing to accept a stockout risk of no more than 4%.

How much safety stock should be held?

What reorder point should be used?

ROP for variable demand and constant lead time

Only demand is variable

Average daily or weekly demand

Standard deviation of demand per day or week

Lead time in days or weeks

d

d

ROP d LT z LT

where

d

LT

Example

A restaurant uses an average of 50 jar of a special sauce each

week. Weekly usage of sauce has a standard deviation of 3 jars.

The manager is willing to accept no more than a 10% risk of

stockout during lead time, which is two weeks. Assume the

distribution of usage is normal.

Determine the value of z

Determine the ROP

ROP for variable lead time and constant demand

Only lead time is variable

aily or weekly demand

Standard deviation of lead time per day or week

Average lead time in days or weeks

LT

LT

ROP d LT zd

where

d D

LT

Problem

The housekeeping department of a motel uses approximately 600

bars of soap per day, and this tends to be fairly constant. Lead

time for soap delivery is normally distributed with a mean of six

days and standard deviation of two days. A service lead of 98% is

desired. Find the ROP.

ROP for variable demand and variable lead time

Both demand and lead time are variable

2 2 2

d LTROP d LT z LT d

Problem

The motel replaces broken glasses at a rate of 25 per day. In the

past, this quantity has tend to vary normally and have a standard

deviation of 3 glasses per day. Glasses are ordered from a

Cleveland supplier. Lead time is normally distributed with an

average of 10 days and a standard deviation of 2 days. What

ROP should be used to achieve a service level of 95%?

Problem

The manager of FSF has determined that demand

for hot dogs obeys a normal distribution with an

average of 5000 per week and standard deviation

of 150 per week.

The manager is willing to accept 3% stockout

risk during lead time which is one week.

Determine the reorder point

Problem

The manager of FSF has determined that demand for hot dogs is approximately 5000 per week and it is fairly constant.

The lead time obeys a normal distribution with an average of one week and standard deviation of 0.5 weeks.

Determine the reorder point if the manager is willing to accept 8% stockout risk.

Problem

The manager of FSF has determined that demand for hot dogs obeys a normal distribution with an average of 5000 per week and standard deviation of 150 per week.

In the past the lead time had a normal distribution with mean of one week and standard deviation of 0.5 weeks

The manager is willing to accept 3% stockout risk during lead time.

Determine the reorder point

Shortages per cycle

The expected number of units short can be very useful

to management.

This quantity can easily be determined using the

information for ROP and Table 11.3 in your textbook.

E(n), expected number of units short per order cycle:

( ) ( ) dLTE n E z

( ) Standardized number of units short from Table 11.3

standard deviation of demand during lead timedLT

E z

Example

Suppose the standard deviation of demand during

lead time is known to be 50 units. Lead time

demand is approximately normal.

For the lead time service level of 95%, determine

the expected number of units short for any order

cycle.

What lead time service level would an expected

shortage of 3 units imply?

Shortages per year

Expected number of units short per year =

(Expected number of units short per cycle) *( Number of cycles)

( ) ( )D

E N E nQ

Example

Given the following information, determine the expected

number of units short per year.

Demand = 48,000 units per year

Order quantity (Q) = 1,200 units

Service level for the lead time = 90%

Std. of demand during lead time = 150 units

How the expected number of units short would change, if

the service level is increases from 90% to 99%?

Annual service level (fill rate)

Annual service level (fill rate) is the percentage of demand

filled directly from inventory.

Example

Demand = 100 units/year,

Annual shortage = 10 units

Annual service level = 90/100 = 90%

General formula:

( )1annual

E NSL

D

Example

Given

A lead time service level of 85%

D = 48,000

Q = 1,200

Std. of demand during lead time = 150

Determine the annual service level

Problem

The manager of a store that sells office supplies has decided to set an annual service level of 96% for a certain model of answering machine. The store sells approximately 300 of this model a year. Holding cost is $5 per unit annually. Ordering cost is $25, and the standard deviation of demand during lead time is 7.

What average number of units short per year will be consistent with the specified annual service level?

What average number of units short per cycle will provide the desired annual service level?

What lead time service level is necessary for the 96% annual service level?

In EOQ/ROP, order size is fixed and time to reorder varies.

In FOI model, orders are placed at fixed time intervals (weekly, monthly, etc.)

Order quantity for next interval?

If demand is variable, order size may vary from cycle to cycle

Fixed-Order-Interval (FOI) Model

Suppliers might encourage fixed intervals

May require only periodic checks of inventory levels

Risk of stockout

FOI must have stockout protection for lead time plus the next order cycle

Reasons for using FOI model

Fixed-Order-Interval Model

Expected demandAmount Safety Amount on hand

= during protection +to order stock at reorder time

interval

= ( ) + dd OI LT z OI LT A

Where

OI = Order interval (length of time between orders)

A = Amount on hand at reorder time

Example

A lab orders a number of chemicals from the same supplier

every 30 days. Lead time is 5 days. The assistant manager of the

lab must determine how much of one of these chemicals to

order. A check of stock revealed that eleven 25-ml jars are on

hand. Daily usage of the chemicals is approximately normal

with a mean of 15.2 ml per day and a standard deviation of 1.6

ml per day. The desired service level for this chemical is 95%.

How many jars of the chemical should be ordered?

What is the average amount of safety stock of the chemicals?

Single period model: model for ordering of perishables (vegetables, milk, ) and other items with limited useful lives

Shortage cost: generally the unrealized profits per unit

Excess cost: difference between purchase cost and salvage value of items left over at the end of a period

Single Period Model

Example: Uniform distribution

Sweet potatoes are delivered weekly to Caspian restaurant.

Demand varies uniformly between 30 to 50 pounds per week.

Caspian pay 25 cents per pound for potatoes and charges 75

cent per pound for it as a side dish. Unsold potatoes have no

salvage value can cannot be carried over into the next week.

Find

The optimal stocking level.

Its stockout risk.

Example: Normal distribution

Caspian restaurant also serves apple juice. Demand for the juice

is approximately normal with a mean of 35 liters per week and

std of 6 liters per week. If shortage cost is 50 cents and excess

cost is 25 cents per liter, find

The optimal stocking level.

Its stockout risk.

A newsboy can buy the Wall Street Journal newspaper for 20

cents and sell them for 75 cents.

If he buys more paper he can sell, he disposes of the excess

at no additional cost.

If he does not buy enough paper, he loses potential sales

For simplicity, we assume that the demand distribution is

P{demand = 0} = 0.1 P{demand = 1} = 0.3

P{demand = 2} = 0.4 P{demand = 3} = 0.2

Example: Discrete distribution

Problem

Skinners Fish Market buys fresh Boston blue fish daily for

$4.20 per pound and sells it for $5.70 per pound. At the end of

each business day, any remaining blue fish is sold to a producer

of cat food for $2.40 per pound. Daily demand can be

approximated by a normal distribution with a mean of 80

pounds and a standard deviation of 10 pounds. What is the

optimal stocking level?

Problem

Burger Prince buys top-grade ground beef for $1.00 per pound.

A large sign over the entrance guarantees that the meat is fresh

daily. Any leftover meat is sold to the local high school

cafeteria for 80 cents per pound. Four hamburgers can be

prepared from each pound of meat. Burgers sell for 60 cents

each. Labor, overhead, meat, buns, and condiments cost 50

cents per burger. Demand is normally distributed with a mean

of 400 pounds per day and a standard deviation of 50 pounds

per day.

What daily order quantity is optimal?

Continuous stocking levels

Identifies optimal stocking levels

Optimal stocking level balances unit shortage

and excess cost

Discrete stocking levels

Service levels are discrete rather than

continuous

Desired service level is equaled or exceeded

Single Period Model