Inventory Policy Decisions “Every management mistake ends up in inventory.” Michael C. Bergerac Former Chief Executive Revlon, Inc. Chapter 9 CR (2004) Prentice Hall, Inc. 9-1 CONTROLLING Customer service goals • The product • Logistics service • Ord. proc. & info. sys. Transport Strategy • Transport fundamentals • Transport decisions PLANNING Inventory Strategy • Forecasting • Inventory decisions • Purchasing and supply scheduling decisions • Storage fundamentals • Storage decisions ORGANIZING Inventory Decisions in Strategy Location Strategy • Location decisions • The network planning process CR (2004) Prentice Hall, Inc. 9-2 What are Inventories? •Finished product held for sale •Goods in warehouses •Work in process •Goods in transit •Staff hired to meet service needs •Any owned or financially controlled raw material, work in process, and/or finished good or service held in anticipation of a sale but not yet sold CR (2004) Prentice Hall, Inc. 9-3 Where are Inventories? Inbound transportation Production Outbound transportation Finished goods warehousing Customers Receiving Material sources Production materials Finished goods Shipping Inventories in-process Inventory locations CR (2004) Prentice Hall, Inc. 9-4 Reasons for Inventories •Improve customer service -Provides immediacy in product availability •Encourage production, purchase, and transportation economies -Allows for long production runs -Takes advantage of price-quantity discounts -Allows for transport economies from larger shipment sizes •Act as a hedge against price changes -Allows purchasing to take place under most favorable price terms •Protect against uncertainties in demand and lead times -Provides a measure of safety to keep operations running when demand levels and lead times cannot be known for sure •Act as a hedge against contingencies -Buffers against such events as strikes, fires, and disruptions in supply CR (2004) Prentice Hall, Inc. 9-5 Reasons Against Inventories •They consume capital resources that might be put to better use elsewhere in the firm •They too often mask quality problems that would more immediately be solved without their presence •They divert management’s attention away from careful planning and control of the supply and distribution channels by promoting an insular attitude about channel management CR (2004) Prentice Hall, Inc. 9-6 Types of Inventories •Pipeline -Inventories in transit •Speculative -Goods purchased in anticipation of price increases •Regular/Cyclical/Seasonal -Inventories held to meet normal operating needs •Safety -Extra stocks held in anticipation of demand and lead time uncertainties •Obsolete/Dead Stock -Inventories that are of little or no value due to being out of date, spoiled, damaged, etc. 9-7 Nature of Demand •Perpetual demand -Continues well into the foreseeable future •Seasonal demand -Varies with regular peaks and valleys throughout the year Accurately forecasting demand is singly the •Lumpy demand most important factor -Highly variable (3 Mean) in good inventory •Regular demand management -Not highly variable (3 < Mean) •Terminating demand -Demand goes to 0 in foreseeable future •Derived demand -Demand is determined from the demand of another item of which it is a part 9-8 Inventory Management Philosophies •Pull -Draws inventory into the stocking location -Each stocking location is considered independent -Maximizes local control of inventories •Push -Allocates production to stocking locations based on overall demand -Encourages economies of scale in production •Just-in-time -Attempts to synchronize stock flows so as to just meet demand as it occurs -Minimizes the need for inventory CR (2004) Prentice Hall, Inc. 9-9 Inventory Management Philosophies (Cont’d) •Supply-Driven -Supply quantities and timing are unknown -All supply must be accepted and processed -Inventories are controlled through demand •Aggregate Control -Classification of items: ›Groups items according to their sales level based on the 80-20 principle ›Allows different control policies for 3 or more broad product groups CR (2004) Prentice Hall, Inc. 9-10 Pull vs. Push Inventory Philosophies PUSH - Allocate supply to each warehouse based on the forecast for each warehouse PULL - Replenish inventory with order sizes based on specific needs of each warehouse Demand forecast Warehouse #1 Q1 A1 A2 Q2 Plant Warehouse #2 A3 Demand forecast Q3 A = Allocation quantity to each warehouse Q = Requested replenishment quantity by each warehouse CR (2004) Prentice Hall, Inc. Warehouse #3 Demand forecast 9-11 Costs Relevant to Inventory Management •Carrying costs -Cost for holding the inventory over time -The primary cost is the cost of money tied up in inventory, but also includes obsolescence, insurance, personal property taxes, and storage costs -Typically, costs range from the cost of short term capital to about 40%/year. The average is about 25%/year of the item value in inventory. CR (2004) Prentice Hall, Inc. 9-12 Relevant Costs (Cont’d) •Procurement costs -Cost of preparing the order -Cost of order transmission -Cost of production setup if appropriate -Cost of materials handling or processing at the receiving dock -Price of the goods CR (2004) Prentice Hall, Inc. 9-13 Relevant Costs (Cont’d) •Out-of-stock costs -Lost sales cost ›Profit immediately foregone ›Future profits foregone through loss of goodwill -Backorder cost ›Costs of extra order handling ›Additional transportation and handling costs ›Possibly additional setup costs CR (2004) Prentice Hall, Inc. 9-14 Inventory Management Objectives Good inventory management is a careful balancing act between stock availability and the cost of holding inventory. Customer Service, i.e., Stock Availability Inventory Holding costs •Service objectives -Setting stocking levels so that there is only a specified probability of running out of stock •Cost objectives -Balancing conflicting costs to find the most economical replenishment quantities and timing CR (2004) Prentice Hall, Inc. 9-15 Inventory’s Conflicting Cost Patterns Minimum cost reorder quantity Cost Total cost Procurement cost Stockout cost CR (2004) Prentice Hall, Inc. Replenishment quantity 9-16 Glossary of Terms D = average annual demand, units d = average period demand, units S = procurement cost per order, $/order I = carrying costs as a percent of product value, % per year C = product value, $ per unit sd = standard deviation of demand (d), units k = out - of - stock cost, $ per unit p = purchase price s ' = standard deviation of compound demand distribution E( z ) = partial expectation or unit normal loss integral P = probability of being in - stock during lead time (Q - system) or during lead time plus order cycle time (P - system Q = order quantity ROP = reorder point quantity, units T = order interval, e.g., days MAX = target inventory level, units z = normal deviate or number of standard deviations from mean on compound demand distribution r = safety stock, or z x s' , units TC = total relevant cost, $ SL = service level as a percent of total annual demand LT , sLT = average and standard deviation of lead time CPn = probability of n units being sold 9-17 Single Order Purchasing Make a one-time purchase of an item. How much to order? Procedure: Balance incremental profit against incremental loss. Profit = Price per unit Cost per unit Loss = Cost per unit Salvage value per unit If CPn is probability of n units being sold, then CPn x Loss = (1 CPn) x Profit or CPn = Profit/(Profit + Loss) Daily stocking of newspapers in vending machines is a good example Now, increase order quantity until CPn just matches cumulative probability of selling additional units. CR (2004) Prentice Hall, Inc. 9-18 Single Order Purchasing (Cont’d) Example A clothing item is purchased for a seasonal sale. It costs $35, but it has a sale price of $50. After the season is over, it is marked down by 50% to clear the merchandise. The estimated quantities to be sold are: Probability of Number of selling exactly n items, n items 10 0.15 15 0.20 20 0.30 25 0.20 30 0.10 35 0.05 1.00 CR (2004) Prentice Hall, Inc. Cumulative probability 0.15 0.35 0.65 0.85 0.95 1.00 9-19 Single Order Purchasing (Cont’d) Solution Profit = $50 35 = $15 Loss = $35 (0.5)(50) = $10 CPn = 15/(15 + 10) = 0.60 CPn is between 15 and 20 items, round up and order 20 items. CR (2004) Prentice Hall, Inc. 9-20 Simple Two-Bin Pull Method Given: d = 50 units/week I = 10%/year S = $10/order C = $5/unit LT = 3 weeks Note: No uncertainty in demand or lead time—manage regular (cycle) stock only Develop a simple control system by finding the replenishment quantity (Q) and the reorder point (ROP). The relevant total cost is: TC = ordering cost carrying costs = DS ICQ 2 Q 9-21 Reorder Point Method Under Certainty for a Single Item Quantity on-hand plus on-order Q Reorder point, R 0 CR (2004) Prentice Hall, Inc. Lead time Order Order Placed Received Lead Time time Order Order Placed Received 9-22 Two-Bin Method (Cont’d) Using differential calculus, the optimal value for Q will be: Q* = 2DS/IC = 2(50x52)(10)/(0.10x5) = 322 units The reorder point is: Famous EOQ formula ROP = d(LT) = 3(50) = 150 units Rule When the inventory level drops to 150 units (ROP) then reorder 322 units (Q*). CR (2004) Prentice Hall, Inc. 9-23 Reorder Point Control with Demand Uncertainty Given: d = 50 units/week sd = 10 units/week I = 10%/year S = $10/order C = $5/unit LT = 3 weeks P = 99% during lead time Find Q* and ROP From the EOQ formula Q* = 2(50x52)(10) = 322 units 0.10(5) CR (2004) Prentice Hall, Inc. Good method for products: 1. Of high value 2. That are purchased from one vendor or plant 3. Having few economies of scale in production, purchasing, or transportation 9-24 Quantity on hand Reorder Point Control for a Single Item Q Place order Q DDLT ROP Receive order 0 P Stockout LT LT Time CR (2004) Prentice Hall, Inc. 9-25 Reorder Point Control for a Single Item Quantity on hand +on order backorders Inventory level Quantity for control Actual on hand Q ROP Safety stock 0 LT CR (2004) Prentice Hall, Inc. Time LT 9-26 Reorder Point Control (Cont’d) Finding the reorder point requires an understanding of the demand-during-lead-time distribution DDLT P Week 1 Week 2 + Week 3 = + sd=10 sd=10 sd=10 d =100 d =100 d =100 Weekly demand is normally distributed with a mean of d = 100 and a standard deviation of sd = 10 Lead time is 3 weeks S’=17.3 z X = 300 ROP X = d LT = 100(3) = 300 s ' = sd LT = 10 3 = 17.3 9-27 Reorder Point Control (Cont’d) Now, X = d(LT ) = 50(3) = 150 units s' = sd LT = 10 3 = 17.32 units Hence, ROP = X zs' = X r = 150 2.33(17.32) = 190 units where 2.33 is the normal deviate at a probability of 0.01 taken from a normal distribution table. CR (2004) Prentice Hall, Inc. 9-28 Reorder Point Control (Cont’d) Total relevant cost The total relevant cost equation is now extended to include the costs of safety stock as well as out-of-stock. The out-of-stock cost (k) is $2/unit. The price term is dropped. Hence, TC = DS IC Q ICr k D s'E(z) 2 Q Q = 2,600(10) (0.1)(5) 322 (0.1)(5)(40) 322 2 2 2,600(17.32)(0.0034) 322 = $182.20 where E(z) = 0.0034 from a unit normal loss table at a z value of 2.33 9-29 Reorder Point Control (Cont’d) With known stockout costs k Setting Q involves balancing both costs and service level at optimum. Since P and Q are interrelated, an iterative approach is required. 1 Solve initially for Q Q = 2DS IC 2 Using Q, find P =1 QIC If backordering is allowed Dk or P =1 QIC Dk QIC If sales are lost CR (2004) Prentice Hall, Inc. 9-30 Reorder Point Control (Cont’d) 3 Using P, find revised Q 2D[S ks' E ] d (z) Q= IC 4 Repeat steps 2 and 3 until no further change 5 Compute ROP and other statistics CR (2004) Prentice Hall, Inc. 9-31 Reorder Point Control (Cont’d) Example Given: Monthly demand forecast, d Std. error of forecast., sd Replenishment lead-time, LT Item value, C Cost for processing vendor order, S Carrying cost, I Stockout cost, k Backordering is allowed 11,107 units 3,099 units 1.5 months $0.11/unit $10/order 20%/year $0.01/unit Find optimal Q and P CR (2004) Prentice Hall, Inc. 9-32 Reorder Point Control (Cont’d) Solution Estimate Q Q = 2DS = 2(11,107)(12)(10) =11,008 units 0.20(0.11) IC Estimate P P =1 QIC = 1 11,008(0.20)(0.11) = 0.82 Dk 11,107(12)(0.01) Revise Q Find App A, z@0.82=0.92 and from App B, E(0.92)=0.0968 For these data, s'd was previously calculated as 3,795 units CR (2004) Prentice Hall, Inc. 9-33 Reorder Point Control (Cont’d) Q= (z) 2DS ks' E d IC = 2(11,107)(12)[(10 0.01(3,795)(0.068)] 0.20(0.11) = 12,872 units Revise P P =1 12,872(0.20)(0.11) = 0.79 11,107(12)(0.01) Now, z@0.81=0.81 and E(0.81)=0.1181 CR (2004) Prentice Hall, Inc. 9-34 Reorder Point Control (Cont’d) Revise Q Q = 2(11,107)(12)[10 0.01(3,795)(0.1181)] =13,246 units 0.20(0.11) Continue to revise Q and P until no further change occurs. P=78% and Q=13,395 units. Note Although the in-stock probability during the lead time is 78%, the actual service level is SL=96% CR (2004) Prentice Hall, Inc. 9-35 Pull Methods (Cont’d) Noninstantaneous resupply At times, production or supply continues while demand is depleting inventories. This requires a slight modification of the EOQ formula. That is, p Qp* = 2DS IC p d Just add this term where p = output or supply rate d = demand rate and p > d. ROP remains unchanged. CR (2004) Prentice Hall, Inc. 9-36 Pull Methods (Cont’d) Reorder point control with demand and lead time uncertainties The combined effect of these two uncertainties is particularly hard to estimate accurately. It is the standard deviation of the demand-during-lead-time distribution that is the problem, especially if the level of demand and the length of the lead time are related to each other. Ideally, we would simply observe the actual demand occurring over each lead time period. If the demand and lead time are independent of each other and each are represented by separate distributions, we may estimate the standard deviation (s′) from 2 ) s' = LT (sd2) d 2(sLT Caution: Can result in very high safety stock levels when lead-time variability is high After computing s’, calculation of the ordering policy would 9-37 be identical to that presented previously. Pull Methods (Cont’d) Periodic review control with demand uncertainty The inventory is reviewed at the time interval (T) to determine the quantity on hand. The replenishment quantity (Q) to be ordered is the difference between a target level called MAX and the quantity on hand. We need to find MAX and T*. Good method for Given: d = 50 units/week sd = 10 units/week I = 10%/year S = $10/order CR (2004) Prentice Hall, Inc. C = $5/unit LT = 3 weeks P = 0.99 k = $2/unit products: 1. Of low value 2. That are purchased from the same vendor 3. Having economies of scale in production, purchasing, and transportation 9-38 Periodic Control for a Single Item Quantity on hand M Q2 ~ Q1 q Stock level reviewed Order received 0 LT T M = maximum level M - q = replenishment quantity LT = lead time Time LT T T = review interval q = quantity on hand Qi = order quantity 9-39 Periodic Review (Cont’d) Estimate Q* from the EOQ formula as if under demand certainty conditions. Recall that this is Q* = 322 units. Now, T* = Q*/d = 322/50 = 6.4 weeks Construct the demand-during-lead-time-plus-ordercycle-time distribution. T is order review time CR (2004) Prentice Hall, Inc. 9-40 Periodic Review (Cont’d) DD(T* + LT) P s′ s = sd T LT ' * CR (2004) Prentice Hall, Inc. Z(s′) X = d(T* + LT) MAX 9-41 Periodic Review (Cont’d) where X = d(T * LT ) = 50(6.4 3) = 470 s' = s T * LT = 10 6.4 3 = 30.66 d Find MAX MAX = d(T* + LT) + z(s’) = 50(6.4 + 3) + 2.33(30.66) = 470 + 71.44 = 541 units Rule Review the inventory every 6.4 weeks and place an order for the difference between the MAX level of 541 units and the quantity on hand + quantity on order – backorders. CR (2004) Prentice Hall, Inc. 9-42 Periodic Review (Cont’d) The total relevant cost for this design is: TC = DS/Q + ICQ/2 + ICr + ks’(D/Q)E(z) = 2600(10)/322 + (.10)(5)(322/2) + (.10)(5)(71) + 2 (30.66)(2600/322)(.0034) = $198 Note Compare this cost with that of the reorder point method to see that periodic review control carries a slight premium in cost due to more safety stock. CR (2004) Prentice Hall, Inc. 9-43 Pull Methods (Cont’d) In/ Date Customer 10/26 Bal Fwd 10/26 100M 10/30 Progression 10/30 Ogleby 11/2 Mid Ross 11/9 Unt Sply 11/29 Berea Lit 12/1 Dol Fed 12/13 Card Fed 12/14 Belmont 12/15 Shkr Sav 1/8 BFK 1/8 100M 1/8 Card Fed 1/9 Pt of View 1/17 Am Safety 1/23 Foster 1/24 Gib Prtg 1/26 Bel-Gar 1/26 Copies 1/29 Slvr Lake 1/29 100M 2/2 Sagamore Size M/Wgt 8½x14 12.72 * Sales 20000 25000 15000 50000 25000 10000 20000 15000 5000 500 30000 10000 5000 15000 5000 5000 20000 5000 20000 Basis 20 On hand Date 80500 2/2 180500 2/5 160500 2/6 135500 2/6 120500 2/6 70500 2/6 45500 2/8 35500 2/14 15500 2/15 500 2/16 500* 2/21 0 2/26 100000 2/27 70000 2/28 60000 2/28 55000 3/1 40000 3/2 35000 3/8 30000 3/8 10000 3/12 5000 3/12 105000 3/12 85000 3/20 Grain Color L White In/ Customer Copies Bel-Gar Bel-Gar Superior Unt Sply Berea Prtg Sagamore 100M 50M Bel-Gar Bel-Gar Inkspot Lcl 25UAW Ptrs Dvl Shkr Sav Copies Untd Tor Sagamore Sagamore 150M Untd Tor Preston Midland Finish RmSeal No stock or insufficient stock to meet demand On Sales hand 50000 35000 5000 30000 15000 15000 25000 0* 15000 0* 15000 0* 5000 0* 100000 150000 5000 145000 15000 130000 5000 125000 50000 75000 2500 72500 25000 47500 35000 12500 10000 2500 2500 0 12500 0* 150000 40000 110000 50000 60000 15000 45000 Grade Advantage Bond In/ Date Customer Sales 3/30 Sup Meats 25000 3/30 Copies 50 3/30 Ptrs Dvl 5000 3/30 Belmont 10000 4/2 Berea Prtg 4950 4/2 Berea Prtg 15050 4/9 REM 500 4/12 Mid Ross 5000 5/7 Ohio Ost 5000 5/8 Inkspots 5000 5/8 Prts Dvl 2500 5/11 100M 5/14 BVR 5000 5/15 Guswold 10000 5/16 ESB 15000 5/16 Superior 50000 5/16 J Stephen 5000 5/16 Am Aster 15000 5/16 Am Aster 10000 5/22 Sagamore 15000 21200 Coding M. Base Cost Date Min 2.64 4/2 Max Location Ctn. Skid Cont. F 14 5M On Hand 20000 19950 14950 4950 0 0* 0* 0* 0* 0* 0* 100000 95000 85000 70000 20000 15000 0 0* 0* 125M 250M Att. 9-44 Pull Methods (Cont’d) Supply chain example Suppose that inventory is to be maintained on a distributor’s shelf for an item whose demand is forecasted to be d = 100 units per day and sd = 10 units per day. A reorder point is the method of inventory control. The supply channel is shown in the diagram. Determine the average inventory to be held at the distributor where we have: I = 10%/year S = $10/order CR (2004) Prentice Hall, Inc. C = $5/unit P = 0.99 during lead time 9-45 Supply Chain Example (Cont’d) Supplier Processing time X p = 1, s 2p = 0 .1 Transport time Inbound transport 2 X i = 4 , si = 1.0 Outbound transport Pool point Transport time X CR (2004) Prentice Hall, Inc. o = 2 , s o2 = 0 .25 Distributor 9-46 Supply Chain Example (Cont’d) Solution The reorder point inventory theory applies. However, determining the statistics of the demandduring-lead-time distribution requires taking the leadtime for the entire channel into account. Recall, 2 s' = LT(sd2 ) d 2(sLT ) where 2 sLT = sp2 si2 so2 = 0.1 1.0 0.25 = 1.35 days CR (2004) Prentice Hall, Inc. 9-47 Supply Chain Example (Cont’d) Average lead time LT = X p X i X o =1 4 2 = 7 days Now s' = 7x102 1002 x1.35 = 14,200 = 119.16 days and Q* = 2(100)(10) = 63 units 0.1(5) * Q AIL = z(s' ) = 63 2.33(199.16) = 309 units 2 2 CR (2004) Prentice Hall, Inc. 9-48 Pull Methods (Cont’d) Joint ordering Perpetual inventory control for most firms is the problem of managing items jointly rather than singly. This occurs since more than one item is typically purchased from the same vendor. The approach to joint ordering is to find a common order review interval (T) and then to set separate target levels (MAX) based on specific item costs and service levels. A common review time may be specified, or it may be computed based on appropriate economics. T* = 2(O S ) i (I C D ) i i CR (2004) Prentice Hall, Inc. where O = common procurement cost, $/order Note: Q* = T*xd 9-49 Joint Ordering Example Given Item A 30 8 14 25 30 Average daily demand (d) Demand std. dev. ( sd) Average lead time (LT) Annual carrying cost (I) Procurement cost (S) with common cost (O) In-stock probability (P) 80 Product value (C) 170 Out-of-stock cost (k) 25 Selling days per year 365 CR (2004) Prentice Hall, Inc. B 75 units 10 units 14 days 25 % 20 $/order 80 $/order 92 % 200 $/unit 45 $/unit 365 days 9-50 Joint Ordering Example (Cont’d) Find common review time T* = 2[80 (30 20)] = 4.35 days [0.25/365][170(30) 200(75)] Find target quantity (MAX) for item A s'A = sd T * LT = 8 4.35 14 = 34.3 units A A then z@80%=0.84 MAX A = X z(sA' ) = 30(4.35 14) 0.84(34.3) = 579 units CR (2004) Prentice Hall, Inc. 9-51 Joint Ordering Example (Cont’d) which has an average inventory of Avg. Inventoryi =T *(di / 2) zi (si' ) Avg. Inventory A = 4.35(30 / 2) 0.84(34.3) = 94.1units Find target quantity (MAX) for item B sB' = sd T * LT = 10 4.35 14 = 42.8 units B B then for z@90%=1.41 MAX B = 75(4.35 14) 1.41(42.8) = 1437 units which has an average inventory of Avg. inventoryB = 4.35(75 / 2) 1.41(42.8) = 223 units CR (2004) Prentice Hall, Inc. 9-52 Pull Methods (Cont’d) The Min-Max variant This is basically a reorder point system, but the order quantity is incremented by the amount of the difference between the reorder point quantity and the quantity on hand + quantity on order backorders. This takes into account that demand does not decrement inventory levels evenly. Therefore, inventory levels may fall below the reorder point at the time that it is reached. CR (2004) Prentice Hall, Inc. 9-53 Min-Max Inventory Control Add increment ROPq to order size Quantity on hand M Q1 ~ Q2 Q* ROP q LT CR (2004) Prentice Hall, Inc. LT Time 9-54 Pull Methods (Cont’d) The T, R, M variant This is a combination of the min-max and the periodic review systems. The stock levels are reviewed periodically, but control the release of the replenishment order by whether the reorder point is reached. This method is useful where demand is low, such that small quantities might be released under a periodic review method. CR (2004) Prentice Hall, Inc. 9-55 Pull Methods (Cont’d) Inventory not below R, so don’t place an order Inventory level T,R,M variant Q1 Q2 R q LT LT T Time T T = review time R = reorder point M – Q = replenishment quantity CR (2004) Prentice Hall, Inc. 9-56 Pull Methods (Cont’d) Stock to demand (a periodic review method) This is an important periodic review method, not so much because of its accuracy but because of its popularity in practice. The method is synchronized with the period of the forecast. The target quantity (MAX) is developed as follows. An example •Set the period of the forecast, say 4 weeks •Add time for lead time, say 1 week •Add an increment of time for safety stock, say 1 week CR (2004) Prentice Hall, Inc. 9-57 Stock to Demand (Cont’d) Therefore, MAX is 6/4 times the monthly forecast. The replenishment quantity is determined as follows. At the time (T) of the monthly stock-level review, make a forecast and determine the MAX level. MAX = Forecast x 6/4 Plus: Backorders Less: Quantity on hand* Less: Quantity on order Order quantity (Q) Units 12,500 0 -5,342 -4,000 3,158 *Quantity on hand = actual quantity on hand + quantity on order – backorders CR (2004) Prentice Hall, Inc. 9-58 Pull Methods (Cont’d) Multiple item, multiple-location control The theory that has been discussed previously is useful when designing inventory control systems for the practical problem of controlling many items at many locations. Consider how a specialty chemical company designed such a practical system. TASO is the time to accumulate a stock order (truckload) for all items in warehouse. CR (2004) Prentice Hall, Inc. 9-59 Q3 Q2 ~ Q1 Stock order Order received ~ 0 LT TASO TASO M = maximum level TASO = time to accumulate stock order CR (2004) Prentice Hall, Inc. LT TASO Time Qi = order quantity LT = lead time Multiple-Item, Multiple-Location Control Quantity on hand M 9-60 Customer Service Level For individual items The service level (stock availability) actually achieved by inventory control methods is not best represented by the probability (P) of a stockout during the lead time. It is more accurate to compute it as follows. SL = 1 s 'E D /Q (z) D = 1 s 'E (z) Q Using data from the reorder point under uncertainty example, the service level would be: SL =1 17.32(.0034)(2,600 / 322) = 0.999 2,600 CR (2004) Prentice Hall, Inc. Note: Higher than P 9-61 Customer Service Level (Cont’d) This actual level is higher than P = 0.99 that was used to set the inventory level. The reason is that there are periods of time when the stock level is above the reorder point and there is no risk of being out of stock. Methods for defining stock availability include: •Probability of filling all item demand •Probability of filling an order completely •Probability of filling a percent of all item demand •Weighted average of items filled on an order (fill rate) CR (2004) Prentice Hall, Inc. 9-62 Customer Service Level (Cont’d) For multiple items on the same order If all items on an order have the same service level, what is the probability of filling the order complete? The service level for multiple items is the combination of the individual item service levels as follows: SL = SL1 x SL2 x SL3 …x SLn Suppose 3 items have the following service levels— 0.95, 0.89, and 0.92. The probability of filling the order complete is: SL = 0.95 x 0.89 x 0.92 = 0.78 CR (2004) Prentice Hall, Inc. 9-63 Push Inventory Control Example Three warehouses are used to supply 900 retail drugstores. Each warehouse serves approximately 300 stores. A large purchase of clock radios is made, where radios were to be a promotional item in the next forecast period. The special buy will result in more stock than needed, but the company expects to sell all stock eventually. Warehouses are to have a 92% in-stock probability. All of the purchased radios are to be allocated to the warehouses based on the anticipated demand levels at each warehouse. Account is taken of the inventory already on hand. A total of 5000 radios is purchased. The next purchase will be made in one month. Further information is given below. CR (2004) Prentice Hall, Inc. 9-64 Push Inventory Control (Cont’d) Warehouse 1 2 3 Current stock level, units 400 350 0 Forecasted demand, units 2,300 1,400 900 4,600 Forecast error (std. dev.), units 100 55 20 How should the allocation to the warehouses be made? CR (2004) Prentice Hall, Inc. 9-65 Push Inventory Control (Cont’d) Solution Warehouse 1 2 3 a2,428 Total requirements a 2,428 1,470 926 4,824 = 2,300 + 1.28(100) Total requirements = Forecast + z(Forecast error) where z@90% = 1.28. Therefore, CR (2004) Prentice Hall, Inc. 9-66 Push Inventory Control (Cont’d) (1) (2) (3)= (4) (5)= Pro(4)+(3) (1)(2) Total Onration Net require- hand requireof AlloWare- ments, stock, ments, excess, cation, house units units units units units a b 1 2,428 400 2,028 463 2,491 2 1,470 350 1,120 282 1,402 3 926 0 926 181 1,107 c Total 4,824 4,074 926 5,000 requirements less (quantity on hand + quantity on order – backorders) bExcess purchase quantity times forecast for warehouse divided by total forecast quantity. For example, (5,000 – 4,074) x 2,300/4,600 = 463 c5,000 – 4,074 = 926 aTotal CR (2004) Prentice Hall, Inc. 9-67 Multi-Echelon Inventories Control the entire channel inventory levels, not just a single echelon. Warehouse echelon Warehouse lead-time, LTw S Supplier ade l tail LT R e R e, tim W R1 R2 d 1 , s d1 d 2 , sd 2 Warehouse R3 End customer demand How much stock here when retailers also carry stock? d 3 , sd3 Retailer CR (2004) Prentice Hall, Inc. 9-68 Multi-Echelon Inventories (Cont’d) Example An item has the following cost characteristics. Item values are CR=$10/unit and CW=$5/unit. Carrying cost is I = 20%/year. Ordering costs are SR=$40/order and SW=$75/order. Lead times are LTR=0.25 month and LTW=0.5 months. In-stock probability for retailers and warehouses is 90%. Monthly demand statistics are: Monthly avg., units Std. dev., units Retailer 1 202.5 16.8 Retailer 2 100.5 15.6 Retailer 3 302.5 18.0 Combined 605.5 32.4 CR (2004) Prentice Hall, Inc. 9-69 Multi-Echelon Inventories (Cont’d) Solution Based on reorder point inventory control, the retailers’ inventory statistics are Retailer 1 Retailer 2 Retailer 3 Reorder qty, Q 312 220 381 Reorder point, ROP 61 35 87 Avg. inv., AIL 167 120 202 The warehouse echelon order quantity is QW = 2DW SW = 2(605.5x12)(75) =1,043.98, or 1,044 units 0.20(5) ICW ROPW = dW xLTW zsW LTW = 605.5(.5) 1.28(32.4) .5 = 332 units CR (2004) Prentice Hall, Inc. 9-70 Multi-Echelon Inventories (Cont’d) The warehouse echelon inventory is QW AILW = zsW LTW 2 = 1,043.98 1.28(32.4) 0.5 2 = 551.32. or 551units The average warehouse inventory is the warehouse echelon inventory less the retailers’ inventory, or 551 – 167 –120 – 202 = 62 units. Rule When the total warehouse inventory (sum of retailers’ inventory, inventory at the warehouse and on order, and retailers’ orders less any inventory committed to customers drops below 332 units, order 1,044 units. CR (2004) Prentice Hall, Inc. 9-71 100 90 Total sales (%) 80 70 60 50 40 30 A items B items C items 20 10 0 0 CR (2004) Prentice Hall, Inc. 20 40 60 Total items (%) 80 100 Aggregate Inventory Control Product items can be grouped according to 80-20 curve, each with different stocking policies 9-72 Inventory Consolidation (“Risk Pooling”) Illustration of risk pooling Suppose there is a product stocked in two warehouses. The replenishment quantities are determined by the economic order quantity formula. The replenishment lead-time is 0.5 months, the cost for a replenishment order is $50, the inventory carrying cost is 2% per month, and the item value is $75 per unit. The probability of an out of stock during the lead-time period is 5%. The demand is normally distributed with typical demand over six months as follows. CR (2004) Prentice Hall, Inc. 9-73 Risk Pooling (Cont’d) 6 Month 1 2 3 4 5 6 Avg. (D) Std. Dev. (sd) Demand in Whse A 35 62 46 25 37 43 41.33 11.38 Combined Demand Demand in a in Whse Central B Whse 67 102 83 145 71 117 62 87 55 92 66 109 67.33 108.66 8.58 19.07 Estimate the average inventory levels for twowarehouse and one-warehouse supply channels. CR (2004) Prentice Hall, Inc. 9-74 Risk Pooling (Cont’d) Regular stock 2DS RS = Q = IC 2 2 2(41.33)(50) 0.02(75) RSA = = 52.49 = 26.25 units 2 2 2(67.33)(50) 0.02(75) RSB = = 67.00 = 33.50 units 2 2 Regular stock in system is RSs = RSA RSB = 26.25 33.50 = 59.75 units CR (2004) Prentice Hall, Inc. 9-75 Risk Pooling (Cont’d) Regular stock if item is entirely in one warehouse 2(108.66)(50) 0.02(75) = 85.11= 42.56 units RSC = 2 2 Safety stock SS = z(sd ) LT SSA = 1.96(11.38) 0.5 = 15.77 units SSB = 1.96(8.58) 0.5 = 11.89 units System safety stock in 2 warehouses SSA SSB = 15.77 11.89 = 27.66 units CR (2004) Prentice Hall, Inc. 9-76 Risk Pooling (Cont’d) Safety stock in 1 warehouse SSc =1.96(19.07) 0.5 = 26.43 units Total inventory AIL = Regular stock + Safety stock Two warehouses AIL = 59.75 + 27.66 = 87.41 units In a one-warehouse channel AIL = 42.56 + 26.43 = 68.99 units Conclusion There is a reduction in the average inventory level of an item as the number of stocking points in the supply channel is decreased. In this example, both regular stock and safety stock decline. CR (2004) Prentice Hall, Inc. 9-77 Risk Pooling (Cont’d) System-wide Inventory as a Fraction of the Demand Divided Between Two Warehouses Percent of Peak System-Wide Inventory 100 95 90 85 80 75 70 0 0.2 0.4 0.6 0.8 1 One warehouse's demand as a fraction of the total CR (2004) Prentice Hall, Inc. 9-78 Virtual Inventories •Stockouts are filled from other stocking locations in the distribution network • Customers assigned to a primary stocking location • Backup locations are usually determined by “zoning” rules • Expectation is that lower system-wide inventories can be achieved while maintaining or improving stock availability levels • Total distribution costs should be lower to support the cross filling of customer demand CR (2004) Prentice Hall, Inc. 9-79 Cross Filling Among 2 Stocking Locations Demand 1 Virtual Inventories Stock location B Secondary assignment Primary assignment Primary assignment Stock location A Demand 2 9-80 Potential Benefit of Cross Filling Suppose that an item is stocked at a fill rate of 80% in 4 stocking locations. If cross filling is used, what is the effective fill rate for the customer? Fill rate = [1 – (.20)(.20)(.20)(.20)] x 100 = 99.8% Customer service levels can be quite high even if the item fill rate is low! But are inventory costs lower? Virtual Inventories CR (2004) Prentice Hall, Inc. 9-81 Regular Stock in 2 Locations Demand 1 Method of stock control Stock location B Secondary assignment Primary assignment Demand dispersion Stock location A Primary assignment •Meaning of regular stock •How it varies with: Demand 2 Fill rate Virtual Inventories CR (2004) Prentice Hall, Inc. 9-82 Stock Control Methods and Regular Stock If control is EOQ-based, average inventory level (AIL) is EOQ formula 2S D AIL = Q = IC 2 2 0.5 = kD0.5 If stock-to-demand control AIL is a function of demand with exponents ranging from 0.5 to 1.0 AIL = kD1.0 Virtual Inventories CR (2004) Prentice Hall, Inc. 9-83 Percent of peak sytem-w ide inventory Regular Stock as a Percent of Demand Divided Stock-toBetween Two Warehouses D0.9 D1.0 demand control 100 95 D0.5 90 D0.7 85 80 75 EOQ-based control 70 0 20 40 60 80 100 O n e w a re h o u s e 's d e m a n d a s a p e rc e n t o f to ta l d e m a n d Virtual Inventories CR (2004) Prentice Hall, Inc. 9-84 Observation about Regular Stock A system of multiple stocking locations will carry its maximum regular stock when demand is balanced among them Virtual Inventories CR (2004) Prentice Hall, Inc. 9-85 Fill Rate and Regular Stock Cross filling increases regular stock as lower fill rates are specified Example •2 locations •Demand is dispersed 50 and 150 •Fill rate is 90% •Stocking policy is D0.5 with k=1 Virtual Inventories CR (2004) Prentice Hall, Inc. 9-86 Example (Cont’d) No cross filling Location A Cross filling Location B Location A Location B 45a 5b Demand 1 50 0 Demand 2 0 150 15 135 Total 50 150 60 140 Regular stock 7.1 12.2 7.7 11.8 System inv. a50x.90=45 b[50x(1-0.90)]x0.905 19.3 19.5 Regular stock increases with cross filling Virtual Inventories CR (2004) Prentice Hall, Inc. 9-87 % of inventory compared w ith no cross-filling Regular Stock Penalty for Cross Filling Under Various Stocking Policies EOQ-based control 150 140 D0.5 130 D0.7 120 D0.9 110 D1.0 100 50 Stock-to-demand control CR (2004) Prentice Hall, Inc. 60 70 80 90 100 A v e ra g e fill ra te o n w a re h o u s e s Virtual Inventories 9-88 Safety Stock in 2 Locations •Meaning of safety stock •Safety stock depends on Demand dispersion (variance is proportional Primary assignment Stock locationB locationB Primary assignment Stock locationA locationA Secondary assignment Demand 1 Demand 2 to (demand) Fill rate Observation A system of multiple stocking locations will carry its minimum safety stock when demand is balanced among them Virtual Inventories CR (2004) Prentice Hall, Inc. 9-89 Safety Stock Estimation Safety stock is estimated by ss = zs * LT where s* is the demand standard deviation at location N When cross filling, s * = FR 2sd2 where sd is the demand standard deviation at the primary location At any location N sN* = [FR(1 FR )N 1]2 sd2 CR (2004) Prentice Hall, Inc. Virtual Inventories 9-90 Safety Stock in 2 Locations Example •2 locations •Weekly demand and std. dev. are (50,5) and (150,15) •Lead time is 1 week •Fill rate (FR) is 95% •z is 1.65 for 95% stocking level (demand normally distributed) •Inventory control is EOQ based Virtual Inventories CR (2004) Prentice Hall, Inc. 9-91 Safety Stock for 2 Locations No cross filling Location A Location B Cross filling Location A Location B Std. Dev. 1 5 0 4.7500 0.2375 Std. Dev. 2 0 15 0.7125 14.2500 Combined 5 15 4.8 14.3 8.3 24.8 7.9 23.5 Safety stock System inv. 33.1 31.4 Safety stock decreases with cross filling Virtual Inventories CR (2004) Prentice Hall, Inc. 9-92 Safety Stock Reduction Due to Cross Filling as a Percent of Demand Divided Between Two Warehouses Percent reduction 25 FR=70% 20 Lower safety stocks from lower fill rates 15 10 FR=90% 5 No crossfilling 0 0 5 15 25 35 45 55 65 75 85 95 100 One warehouse's demand as a percent of the system-wide demand Virtual Inventories CR (2004) Prentice Hall, Inc. 9-93 Simplifying the Decision Problem An item potentially can be cross filled from 1 backup warehouse. The item has a value of $200/unit, a carrying cost of 25%/per year, a stocking level of 6-weeks demand, a replenishment lead-time of 8 weeks, and a target fill rate of 95%. To cross haul the item from the secondary warehouse incurs an extra $10/ unit in transportation. The stock control policy is not known. Demand statistics are as follows: Location Mean demand, units Std. Dev., units 1 300 138 2 100 80 System 400 160 Should the item be cross filled? CR (2004) Prentice Hall, Inc. Virtual Inventories 9-94 Simplifying the Decision Answer Solve for K in AIL=KD. K=D1-/TO, where TO is 52 weeks/6 weeks of demand or 8.67. This assumes a control policy based on of 0.7. Hence, K=(400x52)1-.7/8.67=2.28. The demand ratio r between the 2 locations is 100/400=0.25. Now solve for two parameters of the cross-filling curve. 1.7 1 tD X= = 10([400x52]) =1.73 ICK 0.25(200)(2.28) and 1.96(160) 8 = 0.4 Y = zs LT = KD 2.28(400x52)0.7 Now, from the decision curve, don’t cross fill this item. Virtual Inventories 9-95 CR (2004) Prentice Hall, Inc. LEGEND D = annual system demand s = system demand std. dev. C = item unit cost I = annual carrying cost rate (%) K, = inventory control parameters t = transportation rate FR = item fill rate r = ratio of minimum demand to system demand LT = lead-time in demand std. dev. time units z = normal deviate at FR % tD 1 X = ICK Y = Ratio of minimum demand to total demand, r Decision Curve for FR=.95 and =0.7 zs LT KD Below decision curve—don’t cross fill X Virtual Inventories CR (2004) Prentice Hall, Inc. 9-96 Square Root Law of Inventory Consolidation The amount of inventory (regular stock) at multiple stocking points can be estimated by the square root law when •Inventory control at each point is based on EOQ principles •There is an equal amount on inventory at each point The square root law is: IT = Ii n where IT = amount of inventory at one location Ii = amount of inventory at each of n locations n = number of stocking points CR (2004) Prentice Hall, Inc. 9-97 Square Root Law (Cont’d) Example Suppose that there is $1,000,000 of inventory at 3 stocking points for a total of $3,000,000. If it were all consolidated into 1 location, we can expect: IT = 1,000,000 3 = $1,732,051 If we wish to consolidate from 3 to 2 warehouses, the level of inventory in each warehouse would be: I Ii = T = $1,732,051= $1,224,745 1.41 2 For a total system inventory of n x I = 2 x $1,224,745 = $2,449,490. CR (2004) Prentice Hall, Inc. 9-98 Square Root Law (Cont’d) More simply n2 I2 = I1 n 1 where I2 = system inventory in n2 locations I1 = system inventory in n1 locations n2 = no. of new locations n1 = no. of previous locations So, I2 = 3,000,000 2 = 2,449,490 3 CR (2004) Prentice Hall, Inc. 9-99 Warehouse average inventory, Ii ($000s) Inventory-Throughput Curve 3000 2500 2000 Ii = 1.57Di0.72 R = 0.85 1500 1000 500 0 0 CR (2004) Prentice Hall, Inc. 10000 20000 30000 40000 Annual warehouse throughput, Dj ($000s) 50000 9-100 Inventory-Throughput Curve Example Suppose two warehouses with 390,000 lb. and 770,000 lb. of throughput respectively are to be consolidated into a single warehouse with 390,000 + 770,000 = 1,160,000 lb. of annual throughput. How much inventory is likely to be in the single warehouse? The inventory-throughput curve developed from the company’s multiple warehouse stocks is shown in the figure below. Note Reading from the plot, the inventory in the consolidated warehouse has dropped to 262,000 lb. from 132,000 + 203,000 = 335,000 lb. in the two warehouses. CR (2004) Prentice Hall, Inc. 9-101 Inventory-Throughput Curve 450 Average inventory level, AIL i (000 lb.) 400 350 AILi = 3.12Di0.628 R2 = 0.77 300 262 250 203 200 150 132 100 Current warehouse 50 Consolidated warehouse 0 0 200 400 600 800 1000 1200 1400 1600 1800 Annual warehouse throughput,D i (000 lb.) CR (2004) Prentice Hall, Inc. 9-102 Turnover Ratio Annual sales Turnover ratio = Average inventory A fruit grower stocks its dried fruit products in 12 warehouses around the country. What is the turnover ratio for the distribution system? Warehouse no. 1 2 3 4 5 6 Annual Average warehouse inventory throughput, $ level, $ 21,136,032 2,217,790 16,174,988 2,196,364 78,559,012 9,510,027 17,102,486 2,085,246 88,228,672 11,443,489 40,884,400 5,293,539 TO ratio = $425,295,236 = 9.7 $43,701,344 CR (2004) Prentice Hall, Inc. Warehouse no. 7 8 9 10 11 12 Totals Annual warehouse throughput, $ 43,105,917 47,136,632 24,745,328 57,789,509 16,483,970 26,368,290 425,295,236 Average inventory level, $ 6,542,079 5,722,640 2,641,138 6,403,076 1,991,016 2,719,330 43,701,344 $ are at cost 9-103 Areas under Standardized Normal Distribution CR (2004) Prentice Hall, Inc. A table entry is the proportion of the area under the curve from a z of 0 to a positive value of z. To find the area from a z of 0 to a negative z, subtract the tabled value from 1. z 0.0 0.1 0.2 0.3 0.4 .00 0.5000 0.5398 0.5793 0.6179 0.6554 .01 0.5040 0.5438 0.5832 0.6217 0.6591 .02 0.5080 0.5478 0.5871 0.6255 0.6628 .03 0.5120 0.5517 0.5910 0.6293 0.6664 .04 0.5160 0.5557 0.5948 0.6331 0.6700 .05 0.5199 0.5596 0.5987 0.6368 0.6736 .06 0.5239 0.5636 0.6026 0.6406 0.6772 .07 0.5279 0.5675 0.6064 0.6443 0.6808 .08 0.5319 0.5714 0.6103 0.6480 0.6844 .09 0.5359 0.5753 0.6141 0.6517 0.6879 0.5 0.6 0.7 0.8 0.9 0.6915 0.7257 0.7580 0.7881 0.8159 0.6950 0.7291 0.7611 0.7910 0.8186 0.6985 0.7324 0.7642 0.7939 0.8212 0.7019 0.7357 0.7673 0.7967 0.8238 0.7054 0.7389 0.7704 0.7995 0.8264 0.7088 0.7422 0.7734 0.8023 0.8289 0.7123 0.7454 0.7764 0.8051 0.8315 0.7157 0.7486 0.7794 0.8078 0.8340 0.7190 0.7517 0.7823 0.8106 0.8365 0.7224 0.7549 0.7852 0.8133 0.8389 1.0 1.1 1.2 1.3 1.4 0.8413 0.8643 0.8849 0.9032 0.9192 0.8438 0.8665 0.8869 0.9049 0.9207 0.8461 0.8686 0.8888 0.9066 0.9222 0.8485 0.8708 0.8907 0.9082 0.9236 0.8508 0.8729 0.8925 0.9099 0.9251 0.8531 0.8749 0.8944 0.9115 0.9265 0.8554 0.8770 0.8962 0.9131 0.9279 0.8577 0.8790 0.8980 0.9147 0.9292 0.8599 0.8810 0.8997 0.9162 0.9306 0.8621 0.8830 0.9015 0.9177 0.9319 1.5 1.6 1.7 1.8 1.9 0.9332 0.9452 0.9554 0.9641 0.9713 0.9345 0.9463 0.9564 0.9649 0.9719 0.9357 0.9474 0.9573 0.9656 0.9726 0.9370 0.9484 0.9582 0.9664 0.9732 0.9382 0.9495 0.9591 0.9671 0.9738 0.9394 0.9505 0.9599 0.9678 0.9744 0.9406 0.9515 0.9608 0.9686 0.9750 0.9418 0.9525 0.9616 0.9693 0.9756 0.9429 0.9535 0.9625 0.9699 0.9761 0.9441 0.9545 0.9633 0.9706 0.9767 2.0 2.1 2.2 2.3 2.4 0.9772 0.9821 0.9861 0.9893 0.9918 0.9778 0.9826 0.9864 0.9896 0.9920 0.9783 0.9830 0.9868 0.9898 0.9922 0.9788 0.9834 0.9871 0.9901 0.9925 0.9793 0.9838 0.9875 0.9904 0.9927 0.9798 0.9842 0.9878 0.9906 0.9929 0.9803 0.9846 0.9881 0.9909 0.9931 0.9808 0.9850 0.9884 0.9911 0.9932 0.9812 0.9854 0.9887 0.9913 0.9934 0.9817 0.9857 0.9890 0.9916 0.9936 2.5 2.6 2.7 2.8 2.9 0.9938 0.9953 0.9965 0.9974 0.9981 0.9940 0.9955 0.9966 0.9975 0.9982 0.9941 0.9956 0.9967 0.9976 0.9982 0.9943 0.9957 0.9968 0.9977 0.9983 0.9945 0.9959 0.9969 0.9977 0.9984 0.9946 0.9960 0.9970 0.9978 0.9984 0.9948 0.9961 0.9971 0.9979 0.9985 0.9949 0.9962 0.9972 0.9979 0.9985 0.9951 0.9963 0.9973 0.9980 0.9986 0.9952 0.9964 0.9974 0.9981 0.9986 3.0 3.1 3.2 3.3 3.4 0.9987 0.9990 0.9993 0.9995 0.9997 0.9987 0.9991 0.9993 0.9995 0.9997 0.9987 0.9991 0.9994 0.9995 0.9997 0.9988 0.9991 0.9994 0.9996 0.9997 0.9988 0.9992 0.9994 0.9996 0.9997 0.9989 0.9992 0.9994 0.9996 0.9997 0.9989 0.9992 0.9994 0.9996 0.9997 0.9989 0.9992 0.9995 0.9996 0.9997 0.9990 0.9993 0.9995 0.9996 0.9997 0.9990 0.9993 0.9995 0.9997 0.9998 9-104 Unit Normal Loss Integrals CR (2004) Prentice Hall, Inc. 9-105