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Inventory Management, Supply Contracts and Risk Pooling Phil Kaminsky [email protected] February 1, 2007

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Inventory Management, Supply Contracts and Risk Pooling. Phil Kaminsky [email protected]. February 1, 2007. Issues. Inventory Management The Effect of Demand Uncertainty (s,S) Policy Periodic Review Policy Supply Contracts Risk Pooling Centralized vs. Decentralized Systems - PowerPoint PPT Presentation

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Page 1: Inventory Management, Supply Contracts and Risk Pooling

Inventory Management, Supply Contracts and Risk

Pooling

Phil [email protected]

February 1, 2007

Page 2: Inventory Management, Supply Contracts and Risk Pooling

Issues

• Inventory Management

• The Effect of Demand Uncertainty– (s,S) Policy– Periodic Review Policy– Supply Contracts– Risk Pooling

• Centralized vs. Decentralized Systems

• Practical Issues in Inventory Management

Page 3: Inventory Management, Supply Contracts and Risk Pooling

Supply

Sources:plantsvendorsports

RegionalWarehouses:stocking points

Field Warehouses:stockingpoints

Customers,demandcenterssinks

Production/purchase costs

Inventory &warehousing costs

Transportation costs Inventory &

warehousing costs

Transportation costs

Page 4: Inventory Management, Supply Contracts and Risk Pooling

Inventory• Where do we hold inventory?

– Suppliers and manufacturers– warehouses and distribution centers– retailers

• Types of Inventory– WIP– raw materials– finished goods

• Why do we hold inventory?– Economies of scale– Uncertainty in supply and demand– Lead Time, Capacity limitations

Page 5: Inventory Management, Supply Contracts and Risk Pooling

Goals: Reduce Cost, Improve Service

• By effectively managing inventory:– Xerox eliminated $700 million inventory from

its supply chain– Wal-Mart became the largest retail company

utilizing efficient inventory management– GM has reduced parts inventory and

transportation costs by 26% annually

Page 6: Inventory Management, Supply Contracts and Risk Pooling

Goals: Reduce Cost, Improve Service

• By not managing inventory successfully– In 1994, “IBM continues to struggle with shortages in

their ThinkPad line” (WSJ, Oct 7, 1994)– In 1993, “Liz Claiborne said its unexpected earning

decline is the consequence of higher than anticipated excess inventory” (WSJ, July 15, 1993)

– In 1993, “Dell Computers predicts a loss; Stock plunges. Dell acknowledged that the company was sharply off in its forecast of demand, resulting in inventory write downs” (WSJ, August 1993)

Page 7: Inventory Management, Supply Contracts and Risk Pooling

Understanding Inventory

• The inventory policy is affected by:– Demand Characteristics– Lead Time– Number of Products– Objectives

• Service level• Minimize costs

– Cost Structure

Page 8: Inventory Management, Supply Contracts and Risk Pooling

Cost Structure

• Order costs – Fixed– Variable

• Holding Costs– Insurance– Maintenance and Handling– Taxes– Opportunity Costs– Obsolescence

Page 9: Inventory Management, Supply Contracts and Risk Pooling

EOQ: A Simple Model*

• Book Store Mug Sales– Demand is constant, at 20 units a week– Fixed order cost of $12.00, no lead time– Holding cost of 25% of inventory value

annually– Mugs cost $1.00, sell for $5.00

• Question– How many, when to order?

Page 10: Inventory Management, Supply Contracts and Risk Pooling

EOQ: A View of Inventory*

Time

Inventory

OrderSize

Note:• No Stockouts• Order when no inventory• Order Size determines policy

Avg. Inven

Page 11: Inventory Management, Supply Contracts and Risk Pooling

EOQ: Calculating Total Cost*

• Purchase Cost Constant• Holding Cost: (Avg. Inven) * (Holding

Cost)• Ordering (Setup Cost):

Number of Orders * Order Cost• Goal: Find the Order Quantity that

Minimizes These Costs:

Page 12: Inventory Management, Supply Contracts and Risk Pooling

EOQ:Total Cost*

0

20

40

60

80

100

120

140

160

0 500 1000 1500

Order Quantity

Cos

t

Total Cost

Order Cost

Holding Cost

Page 13: Inventory Management, Supply Contracts and Risk Pooling

EOQ: Optimal Order Quantity*

• Optimal Quantity =

(2*Demand*Setup Cost)/holding cost

• So for our problem, the optimal quantity is 316

Page 14: Inventory Management, Supply Contracts and Risk Pooling

EOQ: Important Observations*

• Tradeoff between set-up costs and holding costs when determining order quantity. In fact, we order so that these costs are equal per unit time

• Total Cost is not particularly sensitive to the optimal order quantity

Order Quantity 50% 80% 90% 100% 110% 120% 150% 200%

Cost Increase 125% 103% 101% 100% 101% 102% 108% 125%

Page 15: Inventory Management, Supply Contracts and Risk Pooling

The Effect of Demand Uncertainty

• Most companies treat the world as if it were predictable:– Production and inventory planning are based on

forecasts of demand made far in advance of the selling season

– Companies are aware of demand uncertainty when they create a forecast, but they design their planning process as if the forecast truly represents reality

• Recent technological advances have increased the level of demand uncertainty:– Short product life cycles – Increasing product variety

Page 16: Inventory Management, Supply Contracts and Risk Pooling

Demand Forecast

• The three principles of all forecasting techniques:

– Forecasting is always wrong– The longer the forecast horizon the worst is

the forecast – Aggregate forecasts are more accurate

Page 17: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Sporting Goods

• Fashion items have short life cycles, high variety of competitors

• SnowTime Sporting Goods – New designs are completed– One production opportunity– Based on past sales, knowledge of the industry, and

economic conditions, the marketing department has a probabilistic forecast

– The forecast averages about 13,000, but there is a chance that demand will be greater or less than this.

Page 18: Inventory Management, Supply Contracts and Risk Pooling

Supply Chain Time Lines

Jan 00 Jan 01 Jan 02

Feb 00 Sep 00 Sep 01

Design Production Retailing

Feb 01Production

Page 19: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Demand Scenarios

Demand Scenarios

0%5%

10%15%20%25%30%

Sales

Pro

babil

ity

Page 20: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Costs

• Production cost per unit (C): $80• Selling price per unit (S): $125• Salvage value per unit (V): $20• Fixed production cost (F): $100,000• Q is production quantity, D demand

• Profit =Revenue - Variable Cost - Fixed Cost + Salvage

Page 21: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Scenarios

• Scenario One:– Suppose you make 12,000 jackets and demand ends

up being 13,000 jackets.– Profit = 125(12,000) - 80(12,000) - 100,000 =

$440,000• Scenario Two:

– Suppose you make 12,000 jackets and demand ends up being 11,000 jackets.

– Profit = 125(11,000) - 80(12,000) - 100,000 + 20(1000) = $ 335,000

Page 22: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Best Solution

• Find order quantity that maximizes weighted average profit.

• Question: Will this quantity be less than, equal to, or greater than average demand?

Page 23: Inventory Management, Supply Contracts and Risk Pooling

What to Make?

• Question: Will this quantity be less than, equal to, or greater than average demand?

• Average demand is 13,100• Look at marginal cost Vs. marginal profit

– if extra jacket sold, profit is 125-80 = 45– if not sold, cost is 80-20 = 60

• So we will make less than average

Page 24: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Expected Profit

Expected Profit

$0

$100,000

$200,000

$300,000

$400,000

8000 12000 16000 20000

Order Quantity

Prof

it

Page 25: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Expected Profit

Expected Profit

$0

$100,000

$200,000

$300,000

$400,000

8000 12000 16000 20000

Order Quantity

Prof

it

Page 26: Inventory Management, Supply Contracts and Risk Pooling

SnowTime: Important Observations

• Tradeoff between ordering enough to meet demand and ordering too much

• Several quantities have the same average profit• Average profit does not tell the whole story

• Question: 9000 and 16000 units lead to about the same average profit, so which do we prefer?

Page 27: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Expected Profit

Expected Profit

$0

$100,000

$200,000

$300,000

$400,000

8000 12000 16000 20000

Order Quantity

Prof

it

Page 28: Inventory Management, Supply Contracts and Risk Pooling

Probability of Outcomes

0%

20%

40%

60%

80%

100%

Revenue

Pro

babi

lity

Q=9000

Q=16000

Page 29: Inventory Management, Supply Contracts and Risk Pooling

Key Insights from this Model

• The optimal order quantity is not necessarily equal to average forecast demand

• The optimal quantity depends on the relationship between marginal profit and marginal cost

• As order quantity increases, average profit first increases and then decreases

• As production quantity increases, risk increases. In other words, the probability of large gains and of large losses increases

Page 30: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Costs: Initial Inventory

• Production cost per unit (C): $80• Selling price per unit (S): $125• Salvage value per unit (V): $20• Fixed production cost (F): $100,000• Q is production quantity, D demand

• Profit =Revenue - Variable Cost - Fixed Cost + Salvage

Page 31: Inventory Management, Supply Contracts and Risk Pooling

SnowTime Expected Profit

Expected Profit

$0

$100,000

$200,000

$300,000

$400,000

8000 12000 16000 20000

Order Quantity

Prof

it

Page 32: Inventory Management, Supply Contracts and Risk Pooling

Initial Inventory

• Suppose that one of the jacket designs is a model produced last year.

• Some inventory is left from last year• Assume the same demand pattern as before• If only old inventory is sold, no setup cost

• Question: If there are 7000 units remaining, what should SnowTime do? What should they do if there are 10,000 remaining?

Page 33: Inventory Management, Supply Contracts and Risk Pooling

Initial Inventory and Profit

0100000200000300000400000500000

Production Quantity

Prof

it

Page 34: Inventory Management, Supply Contracts and Risk Pooling

Initial Inventory and Profit

0100000200000300000400000500000

Production Quantity

Prof

it

Page 35: Inventory Management, Supply Contracts and Risk Pooling

Initial Inventory and Profit

0100000200000300000400000500000

Production Quantity

Prof

it

Page 36: Inventory Management, Supply Contracts and Risk Pooling

Initial Inventory and Profit

0100000200000300000400000500000

5000

6000

7000

8000

9000

1000

0

1100

0

1200

0

1300

0

1400

0

1500

0

1600

0

Production Quantity

Prof

it

Page 37: Inventory Management, Supply Contracts and Risk Pooling

Manufacturer Manufacturer DC Retail DC

Stores

Fixed Production Cost =$100,000

Variable Production Cost=$35

Selling Price=$125

Salvage Value=$20

Wholesale Price =$80

Supply Contracts

Page 38: Inventory Management, Supply Contracts and Risk Pooling

Demand Scenarios

Demand Scenarios

0%5%

10%15%20%25%30%

Sales

Pro

babi

lity

Page 39: Inventory Management, Supply Contracts and Risk Pooling

Distributor Expected Profit

Expected Profit

0

100000

200000

300000

400000

500000

6000 8000 10000 12000 14000 16000 18000 20000

Order Quantity

Page 40: Inventory Management, Supply Contracts and Risk Pooling

Distributor Expected Profit

Expected Profit

0

100000

200000

300000

400000

500000

6000 8000 10000 12000 14000 16000 18000 20000

Order Quantity

Page 41: Inventory Management, Supply Contracts and Risk Pooling

Supply Contracts (cont.)

• Distributor optimal order quantity is 12,000 units

• Distributor expected profit is $470,000• Manufacturer profit is $440,000• Supply Chain Profit is $910,000

–Is there anything that the distributor and manufacturer can do to increase the profit of both?

Page 42: Inventory Management, Supply Contracts and Risk Pooling

Manufacturer Manufacturer DC Retail DC

Stores

Fixed Production Cost =$100,000

Variable Production Cost=$35

Selling Price=$125

Salvage Value=$20

Wholesale Price =$80

Supply Contracts

Page 43: Inventory Management, Supply Contracts and Risk Pooling

Retailer Profit (Buy Back=$55)

0

100,000

200,000

300,000

400,000

500,000

600,000

Order Quantity

Reta

iler P

rofit

Page 44: Inventory Management, Supply Contracts and Risk Pooling

Retailer Profit (Buy Back=$55)

0

100,000

200,000

300,000

400,000

500,000

600,000

Order Quantity

Reta

iler P

rofit

$513,800

Page 45: Inventory Management, Supply Contracts and Risk Pooling

Manufacturer Profit (Buy Back=$55)

0

100,000

200,000

300,000

400,000

500,000

600,000

Production Quantity

Man

ufac

ture

r Pro

fit

Page 46: Inventory Management, Supply Contracts and Risk Pooling

Manufacturer Profit (Buy Back=$55)

0

100,000

200,000

300,000

400,000

500,000

600,000

Production Quantity

Man

ufac

ture

r Pro

fit $471,900

Page 47: Inventory Management, Supply Contracts and Risk Pooling

Manufacturer Manufacturer DC Retail DC

Stores

Fixed Production Cost =$100,000

Variable Production Cost=$35

Selling Price=$125

Salvage Value=$20

Wholesale Price =$??

Supply Contracts

Page 48: Inventory Management, Supply Contracts and Risk Pooling

Retailer Profit (Wholesale Price $70, RS 15%)

0

100,000

200,000

300,000

400,000

500,000

600,000

Order Quantity

Reta

iler P

rofit

Page 49: Inventory Management, Supply Contracts and Risk Pooling

Retailer Profit (Wholesale Price $70, RS 15%)

0

100,000

200,000

300,000

400,000

500,000

600,000

Order Quantity

Reta

iler P

rofit

$504,325

Page 50: Inventory Management, Supply Contracts and Risk Pooling

Manufacturer Profit (Wholesale Price $70, RS 15%)

0

100,000

200,000

300,000

400,000

500,000

600,000

700,000

Production Quantity

Man

ufac

ture

r Pro

fit

Page 51: Inventory Management, Supply Contracts and Risk Pooling

Manufacturer Profit (Wholesale Price $70, RS 15%)

0

100,000

200,000

300,000

400,000

500,000

600,000

700,000

Production Quantity

Man

ufac

ture

r Pro

fit $481,375

Page 52: Inventory Management, Supply Contracts and Risk Pooling

Supply Contracts

Strategy Retailer Manufacturer TotalSequential Optimization 470,700 440,000 910,700 Buyback 513,800 471,900 985,700 Revenue Sharing 504,325 481,375 985,700

Page 53: Inventory Management, Supply Contracts and Risk Pooling

Manufacturer Manufacturer DC Retail DC

Stores

Fixed Production Cost =$100,000

Variable Production Cost=$35

Selling Price=$125

Salvage Value=$20

Wholesale Price =$80

Supply Contracts

Page 54: Inventory Management, Supply Contracts and Risk Pooling

Supply Chain Profit

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

Production Quantity

Supp

ly C

hain

Pro

fit

Page 55: Inventory Management, Supply Contracts and Risk Pooling

Supply Chain Profit

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

Production Quantity

Supp

ly C

hain

Pro

fit $1,014,500

Page 56: Inventory Management, Supply Contracts and Risk Pooling

Supply Contracts

Strategy Retailer Manufacturer TotalSequential Optimization 470,700 440,000 910,700 Buyback 513,800 471,900 985,700 Revenue Sharing 504,325 481,375 985,700 Global Optimization 1,014,500

Page 57: Inventory Management, Supply Contracts and Risk Pooling

Supply Contracts: Key Insights

• Effective supply contracts allow supply chain partners to replace sequential optimization by global optimization

• Buy Back and Revenue Sharing contracts achieve this objective through risk sharing

Page 58: Inventory Management, Supply Contracts and Risk Pooling

Contracts and Supply Chain Performance

• Contracts for Product Availability and Supply Chain Profits– Buyback Contracts– Revenue-Sharing Contracts– Quantity Flexibility Contracts

• Contracts to Coordinate Supply Chain Costs• Contracts to Increase Agent Effort• Contracts to Induce Performance Improvement

Page 59: Inventory Management, Supply Contracts and Risk Pooling

Contracts for Product Availability and Supply Chain Profits

• Many shortcomings in supply chain performance occur because the buyer and supplier are separate organizations and each tries to optimize its own profit

• Total supply chain profits might therefore be lower than if the supply chain coordinated actions to have a common objective of maximizing total supply chain profits

• Double marginalization results in suboptimal order quantity

• An approach to dealing with this problem is to design a contract that encourages a buyer to purchase more and increase the level of product availability

• The supplier must share in some of the buyer’s demand uncertainty, however

Page 60: Inventory Management, Supply Contracts and Risk Pooling

Contracts for Product Availability and Supply Chain Profits: Buyback Contracts• Allows a retailer to return unsold inventory up to a

specified amount at an agreed upon price• Increases the optimal order quantity for the retailer,

resulting in higher product availability and higher profits for both the retailer and the supplier

• Most effective for products with low variable cost, such as music, software, books, magazines, and newspapers

• Downside is that buyback contract results in surplus inventory that must be disposed of, which increases supply chain costs

• Can also increase information distortion through the supply chain because the supply chain reacts to retail orders, not actual customer demand

Page 61: Inventory Management, Supply Contracts and Risk Pooling

Contracts for Product Availability and Supply Chain Profits: Revenue Sharing Contracts

• The buyer pays a minimal amount for each unit purchased from the supplier but shares a fraction of the revenue for each unit sold

• Decreases the cost per unit charged to the retailer, which effectively decreases the cost of overstocking

• Can result in supply chain information distortion, however, just as in the case of buyback contracts

Page 62: Inventory Management, Supply Contracts and Risk Pooling

Contracts for Product Availability and Supply Chain Profits: Quantity Flexibility

Contracts• Allows the buyer to modify the order (within

limits) as demand visibility increases closer to the point of sale

• Better matching of supply and demand• Increased overall supply chain profits if the

supplier has flexible capacity• Lower levels of information distortion than either

buyback contracts or revenue sharing contracts

Page 63: Inventory Management, Supply Contracts and Risk Pooling

Contracts to CoordinateSupply Chain Costs

• Differences in costs at the buyer and supplier can lead to decisions that increase total supply chain costs

• Example: Replenishment order size placed by the buyer. The buyer’s EOQ does not take into account the supplier’s costs.

• A quantity discount contract may encourage the buyer to purchase a larger quantity (which would be lower costs for the supplier), which would result in lower total supply chain costs

• Quantity discounts lead to information distortion because of order batching

Page 64: Inventory Management, Supply Contracts and Risk Pooling

Contracts to Increase Agent Effort

• There are many instances in a supply chain where an agent acts on the behalf of a principal and the agent’s actions affect the reward for the principal

• Example: A car dealer who sells the cars of a manufacturer, as well as those of other manufacturers

• Examples of contracts to increase agent effort include two-part tariffs and threshold contracts

• Threshold contracts increase information distortion, however

Page 65: Inventory Management, Supply Contracts and Risk Pooling

Contracts to InducePerformance Improvement

• A buyer may want performance improvement from a supplier who otherwise would have little incentive to do so

• A shared savings contract provides the supplier with a fraction of the savings that result from the performance improvement

• Particularly effective where the benefit from improvement accrues primarily to the buyer, but where the effort for the improvement comes primarily from the supplier

Page 66: Inventory Management, Supply Contracts and Risk Pooling

Supply Contracts: Case Study• Example: Demand for a movie newly released

video cassette typically starts high and decreases rapidly– Peak demand last about 10 weeks

• Blockbuster purchases a copy from a studio for $65 and rent for $3– Hence, retailer must rent the tape at least 22 times

before earning profit• Retailers cannot justify purchasing enough to

cover the peak demand– In 1998, 20% of surveyed customers reported that

they could not rent the movie they wanted

Page 67: Inventory Management, Supply Contracts and Risk Pooling

Supply Contracts: Case Study• Starting in 1998 Blockbuster entered a revenue

sharing agreement with the major studios– Studio charges $8 per copy– Blockbuster pays 30-45% of its rental income

• Even if Blockbuster keeps only half of the rental income, the breakeven point is 6 rental per copy

• The impact of revenue sharing on Blockbuster was dramatic– Rentals increased by 75% in test markets– Market share increased from 25% to 31% (The 2nd

largest retailer, Hollywood Entertainment Corp has 5% market share)

Page 68: Inventory Management, Supply Contracts and Risk Pooling

(s, S) Policies• For some starting inventory levels, it is better to

not start production• If we start, we always produce to the same level• Thus, we use an (s,S) policy. If the inventory

level is below s, we produce up to S. • s is the reorder point, and S is the order-up-to

level• The difference between the two levels is driven

by the fixed costs associated with ordering, transportation, or manufacturing

Page 69: Inventory Management, Supply Contracts and Risk Pooling

A Multi-Period Inventory Model

• Often, there are multiple reorder opportunities

• Consider a central distribution facility which orders from a manufacturer and delivers to retailers. The distributor periodically places orders to replenish its inventory

Page 70: Inventory Management, Supply Contracts and Risk Pooling

Reminder: The Normal Distribution

0 10 20 30 40 50 60

Average = 30

Standard Deviation = 5

Standard Deviation = 10

Page 71: Inventory Management, Supply Contracts and Risk Pooling

The DC holds inventory to:

• Satisfy demand during lead time

• Protect against demand uncertainty

• Balance fixed costs and holding costs

Page 72: Inventory Management, Supply Contracts and Risk Pooling

The Multi-Period Continuous

Review Inventory Model• Normally distributed random demand• Fixed order cost plus a cost proportional to

amount ordered.• Inventory cost is charged per item per unit time• If an order arrives and there is no inventory, the

order is lost• The distributor has a required service level. This

is expressed as the the likelihood that the distributor will not stock out during lead time.

• Intuitively, how will this effect our policy?

Page 73: Inventory Management, Supply Contracts and Risk Pooling

A View of (s, S) Policy

Time

Inve

ntor

y Le

vel

S

s

0

LeadTimeLeadTime

Inventory Position

Page 74: Inventory Management, Supply Contracts and Risk Pooling

The (s,S) Policy

• (s, S) Policy: Whenever the inventory position drops below a certain level, s, we order to raise the inventory position to level S.

• The reorder point is a function of:– The Lead Time– Average demand– Demand variability– Service level

Page 75: Inventory Management, Supply Contracts and Risk Pooling

Notation• AVG = average daily demand• STD = standard deviation of daily demand• LT = replenishment lead time in days• h = holding cost of one unit for one day• K = fixed cost• SL = service level (for example, 95%). This implies that

the probability of stocking out is 100%-SL (for example, 5%)

• Also, the Inventory Position at any time is the actual inventory plus items already ordered, but not yet delivered.

Page 76: Inventory Management, Supply Contracts and Risk Pooling

Analysis• The reorder point (s) has two components:

– To account for average demand during lead time:LTAVG

– To account for deviations from average (we call this safety stock)z STD LT

where z is chosen from statistical tables to ensure that the probability of stockouts during leadtime is 100%-SL.

• Since there is a fixed cost, we order more than up to the reorder point:

Q=(2 K AVG)/h• The total order-up-to level is:

S=Q+s

Page 77: Inventory Management, Supply Contracts and Risk Pooling

Example• The distributor has historically observed weekly demand

of:AVG = 44.6 STD = 32.1

Replenishment lead time is 2 weeks, and desired service level SL = 97%

• Average demand during lead time is:44.6 2 = 89.2

• Safety Stock is:1.88 32.1 2 = 85.3

• Reorder point is thus 175, or about 3.9 = (175/44.6) weeks of supply at warehouse and in the pipeline

Page 78: Inventory Management, Supply Contracts and Risk Pooling

Example, Cont.

• Weekly inventory holding cost: 0.87= (0.18x250/52)– Therefore, Q=679

• Order-up-to level thus equals:– Reorder Point + Q = 176+679 = 855

Page 79: Inventory Management, Supply Contracts and Risk Pooling

Periodic Review

• Suppose the distributor places orders every month

• What policy should the distributor use?

• What about the fixed cost?

Page 80: Inventory Management, Supply Contracts and Risk Pooling

Base-Stock PolicyIn

vent

ory

Leve

l

Time

Base-stock Level

0

Inventory Position

r r

L L L

Page 81: Inventory Management, Supply Contracts and Risk Pooling

Periodic Review Policy

• Each review echelon, inventory position is raised to the base-stock level.

• The base-stock level includes two components:– Average demand during r+L days (the time

until the next order arrives):(r+L)*AVG

– Safety stock during that time:z*STD* r+L

Page 82: Inventory Management, Supply Contracts and Risk Pooling

Market Two

Risk Pooling

• Consider these two systems:

Supplier

Warehouse One

Warehouse Two

Market One

Market Two

Supplier WarehouseMarket One

Market Two

Page 83: Inventory Management, Supply Contracts and Risk Pooling

Risk Pooling

• For the same service level, which system will require more inventory? Why?

• For the same total inventory level, which system will have better service? Why?

• What are the factors that affect these answers?

Page 84: Inventory Management, Supply Contracts and Risk Pooling

Risk Pooling Example

• Compare the two systems:– two products– maintain 97% service level– $60 order cost– $.27 weekly holding cost– $1.05 transportation cost per unit in

decentralized system, $1.10 in centralized system

– 1 week lead time

Page 85: Inventory Management, Supply Contracts and Risk Pooling

Risk Pooling Example

Week 1 2 3 4 5 6 7 8

Prod A,Market 1

33 45 37 38 55 30 18 58

Prod A,Market 2

46 35 41 40 26 48 18 55

Prod B,Market 1

0 2 3 0 0 1 3 0

Product B,Market 2

2 4 0 0 3 1 0 0

Page 86: Inventory Management, Supply Contracts and Risk Pooling

Risk Pooling Example

Warehouse Product AVG STD CV

Market 1 A 39.3 13.2 .34

Market 2 A 38.6 12.0 .31

Market 1 B 1.125 1.36 1.21

Market 2 B 1.25 1.58 1.26

Page 87: Inventory Management, Supply Contracts and Risk Pooling

Risk Pooling Example

Warehouse Product AVG STD CV s S Avg. Inven.

% Dec.

Market 1 A 39.3 13.2 .34 65 197 91

Market 2 A 38.6 12.0 .31 62 193 88

Market 1 B 1.125 1.36 1.21 4 29 14 Market 2 B 1.25 1.58 1.26 5 29 15 Cent. A 77.9 20.7 .27 118 304 132 36% Cent B 2.375 1.9 .81 6 39 20 43%

Page 88: Inventory Management, Supply Contracts and Risk Pooling

Risk Pooling:Important Observations

• Centralizing inventory control reduces both safety stock and average inventory level for the same service level.

• This works best for – High coefficient of variation, which increases

required safety stock.– Negatively correlated demand. Why?

• What other kinds of risk pooling will we see?

Page 89: Inventory Management, Supply Contracts and Risk Pooling

To Centralize or not to Centralize

• What is the effect on:– Safety stock?– Service level?– Overhead?– Lead time?– Transportation Costs?

Page 90: Inventory Management, Supply Contracts and Risk Pooling

• Centralized Decision

Supplier

Warehouse

Retailers

Centralized Systems*

Page 91: Inventory Management, Supply Contracts and Risk Pooling

Centralized Distribution Systems*

• Question: How much inventory should management keep at each location?

• A good strategy:– The retailer raises inventory to level Sr each period– The supplier raises the sum of inventory in the

retailer and supplier warehouses and in transit to Ss

– If there is not enough inventory in the warehouse to meet all demands from retailers, it is allocated so that the service level at each of the retailers will be equal.

Page 92: Inventory Management, Supply Contracts and Risk Pooling

Inventory Management: Best Practice

• Periodic inventory reviews• Tight management of usage rates, lead

times and safety stock• ABC approach• Reduced safety stock levels • Shift more inventory, or inventory

ownership, to suppliers • Quantitative approaches

Page 93: Inventory Management, Supply Contracts and Risk Pooling

Changes In Inventory Turnover

• Inventory turnover ratio = annual sales/avg. inventory level

• Inventory turns increased by 30% from 1995 to 1998

• Inventory turns increased by 27% from 1998 to 2000

• Overall the increase is from 8.0 turns per year to over 13 per year over a five year period ending in year 2000.

Page 94: Inventory Management, Supply Contracts and Risk Pooling

Industry Upper Quartile

Median Lower Quartile

Dairy Products 34.4 19.3 9.2 Electronic Component 9.8 5.7 3.7 Electronic Computers 9.4 5.3 3.5

Books: publishing 9.8 2.4 1.3

Household audio & video equipment

6.2 3.4 2.3

Household electrical appliances

8.0 5.0 3.8

Industrial chemical 10.3 6.6 4.4

Inventory Turnover Ratio

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Factors that Drive Reduction in Inventory

• Top management emphasis on inventory reduction (19%)

• Reduce the Number of SKUs in the warehouse (10%)

• Improved forecasting (7%)• Use of sophisticated inventory management

software (6%)• Coordination among supply chain members (6%)• Others

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Factors that Drive Inventory Turns Increase

• Better software for inventory management (16.2%)

• Reduced lead time (15%)• Improved forecasting (10.7%)• Application of SCM principals (9.6%)• More attention to inventory management (6.6%)• Reduction in SKU (5.1%)• Others

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Forecasting

• Recall the three rules• Nevertheless, forecast is critical• General Overview:

– Judgment methods– Market research methods– Time Series methods– Causal methods

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Judgment Methods

• Assemble the opinion of experts• Sales-force composite combines

salespeople’s estimates• Panels of experts – internal, external, both• Delphi method

– Each member surveyed– Opinions are compiled– Each member is given the opportunity to

change his opinion

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Market Research Methods

• Particularly valuable for developing forecasts of newly introduced products

• Market testing– Focus groups assembled.– Responses tested.– Extrapolations to rest of market made.

• Market surveys– Data gathered from potential customers– Interviews, phone-surveys, written surveys, etc.

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Time Series Methods• Past data is used to estimate future data• Examples include

– Moving averages – average of some previous demand points.– Exponential Smoothing – more recent points receive more

weight– Methods for data with trends:

• Regression analysis – fits line to data• Holt’s method – combines exponential smoothing concepts with the

ability to follow a trend– Methods for data with seasonality

• Seasonal decomposition methods (seasonal patterns removed)• Winter’s method: advanced approach based on exponential

smoothing– Complex methods (not clear that these work better)

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Causal Methods

• Forecasts are generated based on data other than the data being predicted

• Examples include:– Inflation rates– GNP– Unemployment rates– Weather– Sales of other products

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Selecting the Appropriate Approach:

• What is the purpose of the forecast?– Gross or detailed estimates?

• What are the dynamics of the system being forecast?– Is it sensitive to economic data?– Is it seasonal? Trending?

• How important is the past in estimating the future?• Different approaches may be appropriate for different

stages of the product lifecycle:– Testing and intro: market research methods, judgment methods– Rapid growth: time series methods– Mature: time series, causal methods (particularly for long-range

planning)• It is typically effective to combine approaches.