chapter 6 quantity & delivery by: paul batchelor, paige frank, matthew johnson, priscilla mak,...
TRANSCRIPT
Chapter 6Quantity & Delivery
By: Paul Batchelor, Paige Frank, Matthew Johnson, Priscilla Mak, Missy McCormick
Why Do We Care?
• Continuous improvement and organizational goals drive management attitudes to quality, quantity and delivery
• Ch 5 – Quality
• Ch 6 – Quantity and Delivery
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Classification of Purchases
• Direct/Indirect Purchases• Types of Requirements
– i.e. raw materials, resale items, packaging, etc.
• Frequency of Purchase• Stock Items
– i.e. whether or not purchases are for stock replenishment
• Physical/Chemical Nature• Transport Type• Monetary Value – ABC Classification
PURCHASES
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
ABC Classification
• Concentrates efforts in the areas of highest payoff• Reduces paperwork and managerial effort, but
maintains a high service coverage• Steps:
1. Calculate purchase value (unit price x number of units)2. Classify the purchase value of each item into groups of high
annual purchase value (A), medium value (B), low value (C)3. Concentrate time and effort on A & B items versus on C items
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Forecasting
• Forecasts of usage, supply, market conditions, technology, price, etc., are always necessary to make good decisions
• Sales forecasts drive the need for raw materials, parts and subassemblies
Purchases
ABC
FORECASTING
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Review of Forecasting Techniques
• Qualitative Forecasting– Gathering opinions from a number of people– Delphi Technique
• Quantitative Forecasting– Using past data to predict the future– Causal Models– Time Series Forecasting
Purchases
ABC
FORECASTING
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Inventory
• Inventory policy has a great influence on purchase quantity decision
• Need to know:– How much to order– When to order– How much to carry
Purchases
ABC
Forecasting
INVENTORY
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Inventory Costs
• Main types of inventory costs– Carrying Costs
– Holding Costs
– Possession Costs
• Other costs– Ordering or Purchase Costs
– Setup Costs
– Stockout Costs
– Price Variation Costs
Purchases
ABC
Forecasting
INVENTORY
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Article: “Poor Inventory Control”
• Areas of investigation:– Bills of Material (BOM)– Receiving Policies– Do You Know Each Part’s ATP?– Engineering Changes– Scrap Reporting– Lead Times– Reorder Triggers– Warehouse Locator System
Purchases
ABC
Forecasting
INVENTORY
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Basic Elements of Carrying Costs
1) Capital Costs
2) Inventory Service Costs
3) Storage Space Costs
4) Inventory Risk Costs
• After carrying costs have been estimated, annual carrying costs can be calculated
Purchases
ABC
Forecasting
Inventory
CARRYING COSTS
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Inventory Carrying Costs
(CC per year) = (avg. inventory value) x (inventory CC as a % of
inventory value)
Avg. inv. value = (avg. inv. in units) x (material unit cost)
Purchases
ABC
Forecasting
Inventory
CARRYING COSTS
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Inventory Carrying Costs
CC = Q/2 x C x I
Where:
CC = carrying cost per year
Q = order quantity for the material
C = delivered unit cost of the material
I = inventory carrying cost for the material, as a % of inventory value
Purchases
ABC
Forecasting
Inventory
CARRYING COSTS
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Forms of Inventory
1) Raw Materials and Purchased Parts
2) Work In Process
3) Finished Goods
4) MRO Items
5) Resale Items
Purchases
ABC
Forecasting
Inventory
Carrying Costs
INVENTORY
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Functions of Inventory
• Roles of Inventory:– Transit or Pipeline Inventories– Cycle Inventories– Buffer/Safety Stocks– Anticipation Inventories– Decoupling Inventories
WHY??
Purchases
ABC
Forecasting
Inventory
Carrying Costs
INVENTORY
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Inventory Systems
• Inventory has costs associated with storage
• Systems developed to decrease stocks:– Just-in-time (JIT)– Kanban– Materials Resource Planning (MRP)
Purchases
ABC
Forecasting
Inventory
Carrying Costs
INVENTORY
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Just-in-Time (J.I.T.)
• What is it?• Goals• Integration with process and production
function– Layout– Automation– standardization
• Quality is the key!– 3 principles
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
J.I.T. Continued• Kanban systems
• What will J.I.T. accomplish?
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Dependent vs. Independent Demand
• Independent– Fixed-Quantity Model– Fixed-Period Model
• Dependent– MRP
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
DEMAND
Models
Service Levels
MRP
Game
Case 6-3
Fixed-Quantity Model
• Reorder when inventory drops to a reorder point
• Consider safety stock
• Calculations– Optimal Order Quantity (EOQ)– Reorder Point
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
MODELS
Service Levels
MRP
Game
Case 6-3
Fixed-Period Model
• Reorder only at review time
• Count inventory at the fixed interval period
• Inventory level should prevent stockouts
• Calculation:– Optimal Order Period
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
MODELS
Service Levels
MRP
Game
Case 6-3
Formula Variables
S = Order cost R = Annual demand K = Carrying cost percentage C = Purchase cost L = Lead time
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
MODELS
Service Levels
MRP
Game
Case 6-3
Example: Fixed-Quantity Model See pg 212-213 of text – Refer to handout
Given:
R = 900 units
K = 25 percent
L = 10 working days
C = $45 / unit
S = $50 / order
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
MODELS
Service Levels
MRP
Game
Case 6-3
Calculation
EOQ
Qopt = √ (2RS / KC)
Qopt = √ (2 * 900 * 50) / (25% * 45)
Qopt = 89 units
Reorder point
P = LR/250 Assume 250 working days
P = (10 * 900) / 250 = 36 units
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
MODELS
Service Levels
MRP
Game
Case 6-3
• Topt = (2S)/(RKC)
• Solution:– R = 900 units– C = $45 / unit– K = 25 percent– S = $50 / order
Example: Fixed-Period Model
Topt = (2S)/(RKC)
Topt = (2)(50)
(900)(0.25)(45)
Topt = 0.1
= 0.1*250 working days
= 25 reorder times per year
Note: 250/25 = 10 working days
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
MODELS
Service Levels
MRP
Game
Case 6-3
Example: Fixed-Period Model
• Reordering every 10 working days minimizes total costs– Carrying costs– Order costs
• Order must meet demand for 20 days:– Review period (10 working days)– Lead time (10 working days)
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
MODELS
Service Levels
MRP
Game
Case 6-3
Safety Stock and Service Levels
• Service Coverage– Percentage of requests that are immediately
served
• Stockout Costs– Loss of business due to running out of
inventory
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
SERVICE LEVELS
MRP
Game
Case 6-3
Safety Stock and Service Levels
• Critical Fractile = Cu/(Cu + Co)
• Where– Cu = the cost of understocking
– Co = the cost of overstocking
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
SERVICE LEVELS
MRP
Game
Case 6-3
Safety Stock and Service Levels
• Critical Fractile:– Difficult to determine– 95% or 19:1– Understocking is generally more costly than
overstocking• Exception: “bait and switch”
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
SERVICE LEVELS
MRP
Game
Case 6-3
MRP
• Used for dependent demand
• Goals of MRP:– Minimize inventory– Maintain high service coverage– Coordinate delivery schedules and
manufacturing and purchasing activities
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
Case 6-3
Case 6-3: Abbey Paquette
Abbey Paquette, Purchasing Agent for Pentz International, has been instructed by the new President to reduce annual inventory carry costs from two and a half million to zero by year end.
Upon further investigation, the firm’s database was filled with outdated, inaccurate information. Much of the inventory still on the system was not actually in stock.
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
Problems
Immediate Problem:– How to cut inventory carrying costs?
Basic Problems:– Lack of internal and external information systems– Poor inventory controls– Poor communication with employees
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
Analysis
• No system to classify inventory
• No knowledge of required inventory
• No forecasting
• May have resulted in unnecessary spending & stockout costs
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
Analysis
• No analysis/system to measure carrying costs– Goal: minimize total annual costs
– Timing considerations
– Obsolescence
• Tradeoff between different costs:– Inventory carrying costs vs. ordering costs
– Inventory carrying costs vs. stockout costs
– Inventory carrying costs vs. safety stock costs
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
Analysis
• Minimal supplier relationships– Inconsistent data
• Top management does not understand purchasing function
• Overabundance of small tasks minimizes time for strategy– Low level of automation
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
Analysis
• Current system of inventory tracking and control is not very useful or accurate
• Employees are not following the system and have not been properly trained on how to use the system
• The quality of the entire process is reduced without the problem being fixed
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
Alternatives1. Immediate reduction of inventory
• Goal: Zero inventory
• Refrain from reordering, until it is absolutely necessary
• Utilize J.I.T.
2. Gradual reduction of inventory• Goal: Some inventory
• Continue to reorder, but in smaller quantities
• May require improved supplier relationships
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
Class Discussion
• Split into 2 groups and prepare to defend why the following should be chosen:
Alternative #1 – Group A
Alternative #2 – Group B
Our Solution …Gradual Reduction of Inventory
(Alternative #1)
Implementation: Short TermTime frame: August to end of December
• Comprehensive Analysis – ABC classification– Supplier relations– EOQ Analysis
• Research information systems– MRP– EDI-INT– Barcode scanning
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
• Choosing information systems.– Consult other employees
• Meet with Isaac Chisholm – Explain issues with Zero inventory– Present the plan of action
Implementation: Short TermTime frame: August to end of December
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
Implementation: Medium Term Time frame: January to the end of December
• Get employee buy-in
• Implement new Information Systems– Barcode inventory management system– Internet-based EDI system
• Hire a consultant
• Train employee to do cycle counting
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
Implementation: Long Term Time frame: January and on
• Continue working with suppliers and employees to achieve a stockless inventory purchasing system– Use checks and balances– Generate feedback from employees
• Analyze the average carrying cost to determine the plan’s success
Purchases
ABC
Forecasting
Inventory
Carrying Costs
Inventory
JIT
Demand
Models
Service Levels
MRP
Game
CASE 6-3
QUESTIONS?
THANK YOU!