Managing Flow Variability: Safety Inventory The Magnitude of Shortages (Out of Stock) The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 1 Managing Flow Variability: Safety Inventory What are the Reasons? The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 2 Managing Flow Variability: Safety Inventory Consumer Reaction The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 3 Managing Flow Variability: Safety Inventory Optimal Service Level: The Newsvendor Problem How do we choose what level of service a firm should offer? Cost of ordering too much: holding cost, salvage Cost of ordering too little: lost of sale, low service level The decision maker balances the expected costs of ordering too much with the expected costs of ordering too little to determine the optimal order quantity. The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 4 Managing Flow Variability: Safety Inventory News Vendor Model; Assimptions Demand is random Distribution of demand is known No initial inventory Set-up cost is zero Single period Zero lead time Linear costs Purchasing (production) Salvage value Revenue Goodwill The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 5 Managing Flow Variability: Safety Inventory Optimal Service Level: The Newsvendor Problem Cost =1800, Sales Price = 2500, Salvage Price = 1700 Underage Cost = 2500-1800 = 700, Overage Cost = 1800-1700 = 100 Demand 100 110 120 130 140 150 160 170 180 190 200 Probability of Demand 0.02 0.05 0.08 0.09 0.11 0.16 0.20 0.15 0.08 0.05 0.01 What is probability of demand to be equal to 130? 0.09 0.35 What is probability of demand to be less than or equal to 140? 0.02+0.05+0.08+0.09+0.11= What is probability of demand to be greater than or equal to 140? 1-0.35+0.11= 0.76 What is probability of demand to be equal to 133? 0 P(R ≥ Q ) = 1-P(R ≤ Q)+P(R = Q) The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 R is quantity of demand Q is the quantity ordered 6 Managing Flow Variability: Safety Inventory Optimal Service Level: The Newsvendor Problem Demand 100 101 102 103 104 105 106 107 108 109 Probability of Demand 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002 0.002 Demand 110 111 112 113 114 115 116 117 118 119 Probability of Demand 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.005 What is probability of demand to be equal to 116? 0.005 What is probability of demand to be less than or equal to 116? 0.02+0.035 = 0.055 What is probability of demand to be greater than or equal to 116? 1-0.055+0.005 = 0.95 What is probability of demand to be equal to 113.3? 0 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 7 Managing Flow Variability: Safety Inventory Optimal Service Level: The Newsvendor Problem Average Demand 100 110 120 130 140 150 160 170 180 190 200 The Newsvendor Problem Probability of Demand 0.02 0.05 0.08 0.09 0.11 0.16 0.20 0.15 0.08 0.05 0.01 What is probability of demand to be equal to 130? 0 What is probability of demand to be less than or equal to 145? 0.02+0.05+0.08+0.09+0.11 = 0.35 What is probability of demand to be greater than or equal to 145? 1-0.35 = 0.65 P(R ≥ Q) = 1-P(R ≤ Q) Ardavan Asef-Vaziri, Oct 2011 8 Managing Flow Variability: Safety Inventory Compute the Average Demand N Average Demand Qi P( R Qi ) i 1 Average Demand = +100×0.02 +110×0.05+120×0.08 +130×0.09+140×0.11 +150×0.16 +160×0.20 +170×0.15 +180×0.08 +190×0.05+200×0.01 Average Demand = 151.6 Qi P( R =Q i ) 100 110 120 130 140 150 160 170 180 190 200 0.02 0.05 0.08 0.09 0.11 0.16 0.20 0.15 0.08 0.05 0.01 How many units should I have to sell 151.6 units (on average)? How many units do I sell (on average) if I have 100 units? The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 9 Managing Flow Variability: Safety Inventory Deamand (Qi) 100 110 120 130 140 150 160 170 180 190 200 Porbability Prob (R ≥ Qi) 0.02 1.00 0.05 0.98 0.08 0.93 0.09 0.85 0.11 0.76 0.16 0.65 0.20 0.49 0.15 0.29 0.08 0.14 0.05 0.06 0.01 0.01 Suppose I have ordered 140 Unities. On average, how many of them are sold? In other words, what is the expected value of the number of sold units? When I can sell all 140 units? I can sell all 140 units if R ≥ 140 Prob(R ≥ 140) = 0.76 The expected number of units sold –for this part- is (0.76)(140) = 106.4 Also, there is 0.02 probability that I sell 100 units 2 units Also, there is 0.05 probability that I sell 110 units5.5 Also, there is 0.08 probability that I sell 120 units 9.6 Also, there is 0.09 probability that I sell 130 units 11.7 106.4 + 2 + 5.5 + 9.6 + 11.7 = 135.2 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 10 Managing Flow Variability: Safety Inventory Deamand (Qi) 100 110 120 130 140 150 160 170 180 190 200 Porbability Prob (R ≥ Qi) 0.02 1.00 0.05 0.98 0.08 0.93 0.09 0.85 0.11 0.76 0.16 0.65 0.20 0.49 0.15 0.29 0.08 0.14 0.05 0.06 0.01 0.01 Suppose I have ordered 140 Unities. On average, how many of them are salvaged? In other words, what is the expected value of the number of salvaged units? 0.02 probability that I sell 100 units. In that case 40 units are salvaged 0.02(40) = .8 0.05 probability to sell 110 30 salvaged 0.05(30)= 1.5 0.08 probability to sell 120 20 salvaged 0.08(20) = 1.6 0.09 probability to sell 130 10 salvaged 0.09(10) =0.9 0.8 + 1.5 + 1.6 + 0.9 = 4.8 Total number Sold 135.2 @ 700 = 94640 Total number Salvaged 4.8 @ -100 = -480 Expected Profit = 94640 – 480 = 94,160 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 11 Managing Flow Variability: Safety Inventory Cumulative Probabilities Qi 100 110 120 130 140 150 160 170 180 190 200 Probabilities P(R =Qi) P(R <Qi) P(R ≥Qi) 0.02 0 1 0.05 0.02 0.98 0.08 0.07 0.93 0.09 0.15 0.85 0.11 0.24 0.76 0.16 0.35 0.65 0.2 0.51 0.49 0.15 0.71 0.29 0.08 0.86 0.14 0.05 0.94 0.06 0.01 0.99 0.01 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 12 Managing Flow Variability: Safety Inventory Number of Units Sold, Salvages Qi 100 110 120 130 140 150 160 170 180 190 200 Probabilities P(R =Qi) P(R <Qi) P(R ≥Qi) 0.02 0 1 0.05 0.02 0.98 0.08 0.07 0.93 0.09 0.15 0.85 0.11 0.24 0.76 0.16 0.35 0.65 0.20 0.51 0.49 0.15 0.71 0.29 0.08 0.86 0.14 0.05 0.94 0.06 0.01 0.99 0.01 The Newsvendor Problem Units Sold Salvage 100 0 109.8 0.2 119.1 0.9 127.6 2.4 135.2 4.8 141.7 8.3 146.6 13.4 149.5 20.5 150.9 29.1 151.5 38.5 151.6 48.4 Ardavan Asef-Vaziri, Oct 2011 Sold@700 Salvaged@-100 13 Managing Flow Variability: Safety Inventory Total Revenue for Different Ordering Policies Qi 100 110 120 130 140 150 160 170 180 190 200 Probabilities P(R =Qi) P(R <Qi) P(R ≥Qi) 0.02 0 1 0.05 0.02 0.98 0.08 0.07 0.93 0.09 0.15 0.85 0.11 0.24 0.76 0.16 0.35 0.65 0.2 0.51 0.49 0.15 0.71 0.29 0.08 0.86 0.14 0.05 0.94 0.06 0.01 0.99 0.01 The Newsvendor Problem Units Sold Salvaged 100 0 109.8 0.2 119.1 0.9 127.6 2.4 135.2 4.8 141.7 8.3 146.6 13.4 149.5 20.5 150.9 29.1 151.5 38.5 151.6 48.4 Ardavan Asef-Vaziri, Oct 2011 Sold 70000 76860 83370 89320 94640 99190 102620 104650 105630 106050 106120 Revenue Salvaged 0 20 90 240 480 830 1340 2050 2910 3850 4840 Total 70000 76840 83280 89080 94160 98360 101280 102600 102720 102200 101280 14 Managing Flow Variability: Safety Inventory Denim Wholesaler; Marginal Analysis The demand for denim is: – 1000 with probability 0.10 – 2000 with probability 0.15 – 3000 with probability 0.15 – 4000 with probability 0.20 Unit Revenue (p ) = 30 Unit purchase cost (c )= 10 Salvage value (v )= 5 Goodwill cost (g )= 0 – 5000 with probability 0.15 – 6000 with probability 0.15 – 7000 with probability 0.10 How much should we order? The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 15 Managing Flow Variability: Safety Inventory Marginal Analysis Marginal analysis: What is the value of an additional unit ordered? Suppose the wholesaler purchases 1000 units What is the value of having the 1001st unit? Marginal Cost: The retailer must salvage the additional unit and losses $5 (10 – 5). P(R ≤ 1000) = 0.1 Expected Marginal Cost = 0.1(5) = 0.5 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 16 Managing Flow Variability: Safety Inventory Marginal Analysis Marginal Profit: The retailer makes and extra profit of $20 (30 – 10) P(R > 1000) = 0.9 Expected Marginal Profit= 0.9(20) = 18 MP ≥ MC Expected Value = 18-0.5 = 17.5 By purchasing an additional unit, the expected profit increases by $17.5 The retailer should purchase at least 1,001 units. The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 17 Managing Flow Variability: Safety Inventory Marginal Analysis Should he purchase 1,002 units? Marginal Cost: $5 salvage P(R ≤ 1001) = 0.1 Expected Marginal Cost = 0.5 Marginal Profit: $20 profit P(R >1002) = 0.9 18 Expected Marginal Profit = 18 Expected Value = 18-0.5 = 17.5 Assuming that the initial purchasing quantity is between 1000 and 2000, then by purchasing an additional unit exactly the same savings will be achieved. Conclusion: Wholesaler should purchase at least 2000 units. The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 18 Managing Flow Variability: Safety Inventory Marginal Analysis Marginal analysis: What is the value of an additional unit ordered? Suppose the retailer purchases 2000 units What is the value of having the 2001st unit? Marginal Cost: The retailer must salvage the additional unit and losses $5 (10 – 5). P(R ≤ 2000) = 0.25 Expected Marginal Cost = 0.25(5) = 1.25 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 19 Managing Flow Variability: Safety Inventory Marginal Analysis Marginal Profit: The retailer makes and extra profit of $20 (30 – 10) P(R > 2000) = 0.75 Expected Marginal Profit= 0.75(20) = 15 MP ≥ MC Expected Value = 15-1.25 = 13.75 By purchasing an additional unit, the expected profit increases by $13.75 The retailer should purchase at least 2,001 units. The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 20 Managing Flow Variability: Safety Inventory Marginal Analysis Should he purchase 2,002 units? Marginal Cost: $5 salvage P(R ≤ 2001) = 0.25 Expected Marginal Cost = 1.25 Marginal Profit: $20 profit P(R >2002) = 0.75 Expected Marginal Profit = 15 Expected Value = 18-0.5 = 13.75 Assuming that the initial purchasing quantity is between 2000 and 3000, then by purchasing an additional unit exactly the same savings will be achieved. Conclusion: Wholesaler should purchase at least 3000 units. The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 21 Managing Flow Variability: Safety Inventory Marginal Analysis Why does the marginal value of an additional unit decrease, as the purchasing quantity increases? – Expected cost of an additional unit increases – Expected savings of an additional unit decreases Cumulative Expected Expected Expected Demand Probability Probability Marginal Cost Marginal Profit Marginal Value 1000 0.10 0.1 0.50 18 17.50 2000 0.15 0.25 1.25 15 13.75 3000 0.15 0.40 2.00 12 10.00 4000 0.20 0.60 3.00 8 5.00 5000 0.15 0.75 3.75 5 1.25 6000 0.15 0.90 4.50 2 -2.50 7000 0.10 1.00 5.00 0 -5.00 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 22 Managing Flow Variability: Safety Inventory Marginal Analysis What is the optimal purchasing quantity? – Answer: Choose the quantity that makes marginal value: zero Marginal value 17.5 13.75 10 5 1.3 Quantity -2.5 1000 2000 3000 4000 5000 6000 7000 8000 -5 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 23 Managing Flow Variability: Safety Inventory Analytical Solution for the Optimal Service Level Marginal Profit: MP = p – c MP = 30 - 10 = 20 Marginal Cost: MC = c - v MC = 10-5 = 5 Suppose I have ordered Q units. What is the expected cost of ordering one more units? What is the expected benefit of ordering one more units? If I have ordered one unit more than Q units, the probability of not selling that extra unit is the probability demand to be less than or equal to Q. Since we have P( R ≤ Q). The expected marginal cost =MC× P( R ≤ Q) The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 24 Managing Flow Variability: Safety Inventory Analytical Solution for the Optimal Service Level If I have ordered one unit more than Q units, the probability of selling that extra unit is the probability of demand to be greater than Q. We know that P(R > Q) = 1- P(R ≤ Q). The expected marginal benefit = MB× [1-Prob.( r ≤ Q)] As long as expected marginal cost is less than expected marginal profit we buy the next unit. We stop as soon as: Expected marginal cost ≥ Expected marginal profit. The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 25 Managing Flow Variability: Safety Inventory Analytical Solution for the Optimal Service Level MC×Prob(R ≤ Q*) ≥ MP× [1 – Prob( R ≤ Q*)] Prob(R ≤ Q*) ≥ MB MB MC MP = p – c = Underage Cost = Cu MC = c – v = Overage Cost = Co P( R Q* ) MP MP MC The Newsvendor Problem cu Cu C o MP MP MC pc pc pccv pv Ardavan Asef-Vaziri, Oct 2011 26 Managing Flow Variability: Safety Inventory Marginal Value: The General Formula P(R ≤ Q*) ≥ Cu / (Co+Cu) Cu / (Co+Cu) = (30-10)/[(10-5)+(30-10)] = 20/25 = 0.8 Order until P(R ≤ Q*) ≥ 0.8 P(R ≤ 5000) ≥ = 0.75 not > 0.8 still order P(R ≤ 6000) ≥ = 0.9 > 0.8 Stop Demand 1000 2000 3000 4000 5000 6000 7000 Probability 0.1 0.15 0.15 0.2 0.15 0.15 0.1 In Continuous Model where demand for example has Uniform or Normal distribution MP cu P( R Q ) MP MC Cu C o * The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 pc pv 27 Managing Flow Variability: Safety Inventory Type-1 Service Level What is the meaning of the number 0.80? 80% of the time all the demand is satisfied. – Probability {demand is smaller than Q} = – Probability {No shortage} = – Probability {All the demand is satisfied from stock} = 0.80 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 28 Managing Flow Variability: Safety Inventory Marginal Value: Uniform distribution Suppose instead of a discreet demand of Demand 1000 2000 3000 4000 5000 6000 7000 Probability 0.1 0.15 0.15 0.2 0.15 0.15 0.1 Cumlat Probab 0.1 0.25 0.4 0.6 0.75 0.9 1 We have a continuous demand uniformly distributed between 1000 and 7000 1000 7000 Pr{r ≤ Q*} = 0.80 How do you find Q? The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 29 Managing Flow Variability: Safety Inventory Marginal Value: Uniform distribution Q-l = Q-1000 ? 0.80 l=1000 1/6000 u=7000 u-l=6000 (Q-1000)/6000=0.80 Q = 5800 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 30 Managing Flow Variability: Safety Inventory Marginal Value: Normal Distribution Suppose the demand is normally distributed with a mean of 4000 and a standard deviation of 1000. What is the optimal order quantity? Notice: F(Q) = 0.80 is correct for all distributions. We only need to find the right value of Q assuming the normal distribution. P(z ≤ Z) = 0.8 Z= 0.842 Q = mean + z Standard Deviation 4000+841 = 4841 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 31 Managing Flow Variability: Safety Inventory Marginal Value: Normal Distribution 0.00045 0.0004 Probability of excess inventory 0.00035 0.0003 Probability of shortage 4841 0.00025 0.0002 0.00015 0.0001 0.80 0.00005 0 0 2000 4000 0.20 6000 8000 Given a service level, how do we calculate z? From our normal table or From Excel Normsinv(service level) The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 32 Managing Flow Variability: Safety Inventory Additional Example Your store is selling calendars, which cost you $6.00 and sell for $12.00 Data from previous years suggest that demand is well described by a normal distribution with mean value 60 and standard deviation 10. Calendars which remain unsold after January are returned to the publisher for a $2.00 "salvage" credit. There is only one opportunity to order the calendars. What is the right number of calendars to order? MC= Overage Cost = Co = Unit Cost – Salvage = 6 – 2 = 4 MB= Underage Cost = Cu = Selling Price – Unit Cost = 12 – 6 = 6 Cu 6 P( R Q ) 0. 6 Cu C o 6 4 * The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 33 Managing Flow Variability: Safety Inventory Additional Example - Solution Look for P(x ≤ Z) = 0.6 in Standard Normal table or for NORMSINV(0.6) in excel 0.2533 Q* Q* P( Z ) 0.6 0.2533 Q* 0.2533 60 10(0.2533) 62.533 63 By convention, for the continuous demand distributions, the results are rounded to the closest integer. Suppose the supplier would like to decrease the unit cost in order to have you increase your order quantity by 20%. What is the minimum decrease (in $) that the supplier has to offer. The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 34 Managing Flow Variability: Safety Inventory Additional Example - Solution Qnew = 1.2 * 63 = 75.6 ~ 76 units 76 60 P( R Q ) P( R 76) P( Z ) P( Z 1.6) 10 * Look for P(Z ≤ 1.6) = 0.6 in Standard Normal table or for NORMSDIST(1.6) in excel 0.9452 Cu pc 12 c 12 c P( R Q ) 0.9452 Cu Co p c c v 12 2 10 * 12 c 9.452 c 2.55 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 35 Managing Flow Variability: Safety Inventory Additional Example On consecutive Sundays, Mac, the owner of your local newsstand, purchases a number of copies of “The Computer Journal”. He pays 25 cents for each copy and sells each for 75 cents. Copies he has not sold during the week can be returned to his supplier for 10 cents each. The supplier is able to salvage the paper for printing future issues. Mac has kept careful records of the demand each week for the journal. The observed demand during the past weeks has the following distribution: Qi 4 5 6 7 8 P(R=Qi) 0.04 0.06 0.16 0.18 0.2 The Newsvendor Problem 9 0.1 Ardavan Asef-Vaziri, Oct 2011 10 0.1 11 12 13 0.08 0.04 0.04 36 Managing Flow Variability: Safety Inventory Additional Example Qi 4 5 6 7 8 P(R=Qi) 0.04 0.06 0.16 0.18 0.2 9 0.1 10 0.1 11 12 13 0.08 0.04 0.04 a) How many units are sold if we have ordered 7 units There is 0.18 + 0.20 + 0.10 + 0.10 + 0.08 + 0.04 + 0.04 = 0.74 There is 0.74 probability that demand is greater than or equal to 7. There is 0.16 probability that demand is equal to 6. There is 0.06 probability that demand is equal to 5. There is 0.04 probability that demand is equal to 4. The expected number of units sold is 0.74(7) + 0.16 (6) + 0.06 (5) + 0.04 (4) = 6.6 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 37 Managing Flow Variability: Safety Inventory Additional Example Qi 4 5 6 7 8 P(R=Qi) 0.04 0.06 0.16 0.18 0.2 9 0.1 10 0.1 11 12 13 0.08 0.04 0.04 b) How many units are salvaged? 7-6.6 = 0.4. Alternatively, we can compute it directly There is 0.74 probability that we salvage 7 – 7 = 0 units There is 0.16 probability that we salvage 7- 6 = 1 units There is 0.06 probability that we salvage 7- 5 = 2 units There is 0.04 probability that we salvage 7-4 = 3 units The expected number of units salvaged is 0.74(0) + 0.16 (1) + 0.06 (2) + 0.04 (3) = 0.4 and 7-0.4 = 6.6 sold The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 38 Managing Flow Variability: Safety Inventory Additional Example c) Compute the total profit if we order 7 units. Out of 7 units, 6.6 sold, 0.4 salvaged. P = 75, c= 25, v=10. Profit per unit sold = 75-25 = 50 Cost per unit salvaged = 25-10 = 15 Total Profit = 6.6(50) + 0.4(15) = 333 - 9 = 324 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 39 Managing Flow Variability: Safety Inventory Additional Example Qi 4 5 6 7 8 P(R=Qi) 0.04 0.06 0.16 0.18 0.2 9 0.1 10 0.1 11 12 13 0.08 0.04 0.04 d) Compute the expected Marginal profit of ordering the 8th unit. MP = 75-25 = 50 P(R ≥ 8) = 0.2 + 0.1 + 0.1 + 0.08 + 0.04 + 0.04 = 0.56 Expected Marginal profit = 0.56(50) = 28 d) Compute the expected Marginal cost of ordering the 8th unit. MC = 25 – 10 = 15 P(R ≤ 7) = 1-0.56 = 0.44 Expected Marginal cost = 0.44(15) = 6.6 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 40 Managing Flow Variability: Safety Inventory Additional Example - Solution e) What is the optimum order quantity for Mac to minimize his cost? Overage Cost = Co = Unit Cost – Salvage = 0.25 – 0.1 = 0.15 Underage Cost = Cu = Selling Price – Unit Cost = 0.75 – 0.25 = 0.50 Cu 0.50 P( R Q*) 0.77 Cu Co 0.50 0.15 P( R Q* ) 0.77 Qi 4 5 6 7 8 9 10 11 12 13 Probability P(R=Qi) 0.04 0.06 0.16 0.18 0.20 0.10 0.10 0.08 0.04 0.04 Cumulative Probability F(Qi) 0.04 0.10 0.26 0.44 0.64 0.74 0.84 0.92 0.96 1.00 Q* = 10 The Newsvendor Problem Ardavan Asef-Vaziri, Oct 2011 41