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LOGO
JJ619
CHAPTER 3INVENTORY CONTROL MANAGEMENT
JJ619
CHAPTER 3INVENTORY CONTROL MANAGEMENT
PREPAREDE BY:MD NAJIP BIN TALIBIN
Course Learning Outcomes
1
2
4
.Upon completion of this course, students should be able to:
apply the basic concept of industrial management system in Industry. Identify the suitable concept industrial management system in related industry by group
Contents
Inventory control and management concept. 1
Inventory cost. 2
Inventory models for independent demand.3
44 Master scheduling.
45 Material Requirement Planning (MRP)
Inventory Control & Management Concept
1
2
4
1
12-4
What Is Inventory?
Inventory is an idle resource which is usable and has value.
Stock of items kept to meet future demandPurpose of inventory management:
how many units to order when to order
Inventory Control & Management Concept
1
2
4
1
12-5
Objective of Inventory
To meet anticipated demand (make-to-stock)
In-Transit inventory: goods being transported
To take advantage of order cycles or to take advantage of quantity discounts (cycle stock)
Inventory Control & Management Concept
1
2
4
1
12-6
Objective of Inventory
To protect against stock-outs (safety stocks).
To smooth production requirements (seasonal inventories).
To decouple production and distribution (WIP buffers).
To help hedge against price increases (speculative inventories).
Inventory Control & Management Concept
1
2
4
1
12-7
General Types of Inventory
Official Inventory Unofficial Inventory
Inventory Control & Management Concept
1
2
4
1
12-8
Types of Inventory
Raw materialsComponents - Purchased parts and suppliesWork-in-process (partially completed) products
(WIP)Items being transported (Finished Goods)Tools and equipment
Inventory Control & Management Concept
1
2
4
1
12-9
Types of Inventory
Inventory Control & Management Concept
1
2
4
1
Inventory Control Systems
Continuous system (fixed-order quantity)• constant amount ordered when inventory
declines to predetermined level.
Periodic system (fixed-time-period)• order placed for variable amount after fixed
passage of time.
Inventory Control & Management Concept
2
4
1
Inventory Costs
Carrying or Holding cost- This broad category includes the costs for
storage facilities, handling, insurance, breakage, taxes and the opportunity cost of capital.
Ordering cost- Refer to the managerial and clerical costs to
prepare the purchase or production order.
2
4
1 Inventory Costs
Shortage cost- Temporary or permanent loss of sales when
demand cannot be met.
Setup Cost- To make each different product involves
obtaining the necessary materials, arranging specific equipment setups, filling out the required paper, charging time & material and moving out the previous stock of material.
Inventory Cost
1
2
4
1
Most Important Inventory Costs
Holding Costs
Denoted H; includes the variable expenses incurred by the plant related to the volume of inventory held e.g. 15-25%
Ordering Cost
Denoted S; fixed, constant money amount incurred for each order placed
1
2
4
3Inventory Model For IndependentDemand
Independent demand items are finished products or parts that are shipped as end items to customers.
Forecasting plays a critical roleDue to uncertainty- extra units must be
carried in inventory.
1
2
4
3Inventory Model For IndependentDemand
Dependent demand items are raw materials, component parts, or subassemblies that are used to produce a finished product.
1
2
4
3Inventory Model For IndependentDemand
Economic Order Quantity (EOQ or Q System)
Economic Production Quantity (EPQ)
Quantity Discount Model
Three Mathematical Models for Determining Order Quantity
1
2
4
3Inventory Model For IndependentDemand
Economic Order Quantity (EOQ or Q System) An optimizing method used for determining order
quantity and reorder points Part of continuous review system which tracks on-
hand inventory each time a withdrawal is made
Economic Production Quantity (EPQ) A model that allows for incremental product delivery
Quantity Discount Model Modifies the EOQ process to consider cases where
quantity discounts are available
1
2
4
3Inventory Model For IndependentDemand
© Wiley 2007
Economic Order Quantity EOQ Assumptions:
Demand is known & constant - no safety stock is required
Lead time is known & constant No quantity discounts are
available Ordering (or setup) costs are
constant All demand is satisfied (no
shortages) The order quantity arrives in a
single shipment
1
2
4
3Inventory Model For IndependentDemand
Total annual cost= annual ordering cost + annual holding costs
H
2DSQ and H;
2
QS
Q
DTCQ
3Inventory Model For IndependentDemand
Continuous (Q) Review System Example: A computer company has annual demand of 10,000. They want to determine EOQ for circuit boards which have an annual holding cost (H) of RM6 per unit, and an ordering cost (S) of RM75. They want to calculate TC and the reorder point (R) if the purchasing lead time is 5 days.
1
2
4
3Inventory Model For IndependentDemand
EOQ (Q)
Reorder Point (R)
Total Inventory Cost (TC)
units 500RM6
RM75*10,000*2
H
2DSQ
units 200days 5*days 250
10,000Time Lead x DemandDaily R
RM3000RM1500RM1500RM62
500RM75
500
10,000TC
1
2
4
3Inventory Model For IndependentDemand
© Wiley 2007
Economic Production Quantity (EPQ) Same assumptions as the EOQ except: inventory
arrives in increments & is drawn down as it arrives
1
2
4
3Inventory Model For IndependentDemand
© Wiley 2007
EPQ Equations
Total cost:
Maximum inventory: d=avg. daily demand rate p=daily production rate
Calculating EPQ
H
2
IS
Q
DTC MAX
EPQ
p
d1QIMAX
p
d1H
2DSEPQ
EPQ Problem: HP Ltd. Produces its premium plant food in 50# bags. Demand is 100,000 kg per week and they operate 50 weeks. each year and HP can produce 250,000kg. per week. The setup cost is RM200 and the annual holding cost rate is RM55 per bag. Calculate the EPQ. Determine the maximum inventory level. Calculate the total cost of using the EPQ policy.
H
2
IS
Q
DTC MAX
EPQ
p
d1H
2DSEPQ
p
d1QIMAX
Inventory Model For IndependentDemand
pd1H
2DSEPQ BagsEPQ 850,77
250000000,100
155.
)200)(000,100)(50(2
p
d1QIMAX
H
2
IS
Q
DTC MAX
EPQ
bagsMAXI 710,46000,250
000,1001850,77
690,2555.2
710,46200
850,77
000,000,5RMTC
Inventory Model For IndependentDemand
Quantity Discount Model
Same as the EOQ model, except: Unit price depends upon the quantity ordered
The total cost equation becomes:
H
2
QS
Q
DTCQD CD
Inventory Model For IndependentDemand
Quantity Discount Procedure
Calculate the EOQ at the lowest priceDetermine whether the EOQ is feasible at
that price Will the vendor sell that quantity at that price?
If yes, stop – if no, continueCheck the feasibility of EOQ at the next
higher price
Continue to the next slide ...
© Wiley 2007
QD Procedure (continued)
Continue until you identify a feasible EOQCalculate the total costs (including total item
cost) for the feasible EOQ modelCalculate the total costs of buying at the
minimum quantity required for each of the cheaper unit prices
Compare the total cost of each option & choose the lowest cost alternative
Any other issues to consider?
LOGO
4 Master Scheduling
Master Scheduling is a business process designed to balance demand and supply at the detailed, mix level.
Master Scheduling is primarily a decision-making process, performed by an individual called the Master Scheduler. As such, it is people-centered; the computer’s role is to support the people in their decision-making activities.
4 Master Scheduling
The output from this process is the Master Production Schedule, which is the anticipated build schedule for specific products (or parts of products) and customer orders.
4 Master Scheduling
The Master Schedule is:
• time-phased,• extends for a number of weeks into the future,• is typically expressed in weekly time increments or smaller.
4 Master Scheduling
Master Production Schedule
Provides basis for: Making good use of manufacturing resources. Making customer delivery promises. Resolving tradeoffs between sales and
manufacturing. Attaining strategic objectives in the sales and
operations plan.
4 Master Scheduling
What is “Master Production Scheduling?”
Start with Aggregate plan (Aggregate Sales & Ops Plan) Output level designed to meet targets
DisaggregatesConverts into specific schedule for each item
Role of the MPS
Aggregate plan: Specifies the resources available (e.g.: regular
workforce, overtime, subcontracting, allowable inventory levels & shortages)
Master production schedule: Specifies the number & when to produce each
end item (the anticipated build schedule) Disaggregates the aggregate plan
4 Master Scheduling
4 Master Scheduling
S&OP vs MPS
“The role of the sales and operations plan is to balance supply and demand volume, while the MPS specifies the mix and volume of the output”
MPS shows when products will be available in future
Planned production, not forecast
4 Master Scheduling
4 Master Scheduling
Planning Links to MPS
4 Master Scheduling
Basic information which are needed to preparethe Master Production Schedule (MPS).
a) When the product is completed and can be sent to the customer.b) How long is the final assemble.c) How long is the process to make sub assembly. d) How long is the component takes time to be completed.
4 Master Scheduling
Basic information which are needed to preparethe Master Production Schedule (MPS).
e) List the number of all quantity material to produce a product.f) List the completed production processes.g) Standard time for each operation.h) Total order quantity from the customer or internal order as in the stock.
Page 41
Objectives of MPS
Maintain the desired customer service levelUtilize resources efficientlyMaintain desired inventory levels
4 Master Scheduling
Zubair Sdn Bhd will produce a new product for 1,000 units. The product has four stages of operation which is shown as below:
Operation Operation Time (hour/unit)
Production Time (hour)
1 2 6002 4 4003 4 4004 6 600
4 Master Scheduling
• Calculate the monthly capacity and the duration of the production.• Draw Master Production Schedule (MPS).• Analyze the data.
LOGOMaterial Requirements Planning (MRP)
Material Requirements Planning (MRP)
Presented by:
MD NAJIP BIN TALIBIN
MNT 2012
Dependent Demand
For any product for which a schedule can be established, dependent
demand techniques should be used
MNT 2012
5Material Requirement Planning (MRP)
MNT 2012
Dependent Demand The demand for one item is related
to the demand for another item Given a quantity for the end item,
the demand for all parts and components can be calculated
In general, used whenever a schedule can be established for an item
MRP is the common technique
5Material Requirement Planning (MRP)
MNT 2012
1. Master production schedule
2. Specifications or bill of material
3. Inventory availability
4. Purchase orders outstanding
5. Lead times
Effective use of dependent demand inventory models requires the following
5Material Requirement Planning (MRP)
Material Requirement Planning (MRP)
Define fundamental of Material Requirement Planning (MRP).
Materials requirements planning (MRP) is the logic for determining the number of parts, components, and materials needed to produce a product.
5
Material Requirement Planning (MRP)
MRP provides time scheduling information specifying when each of the materials, parts, and components should be ordered or produced.
MRP is a Computer-based information system that schedules and orders dependent-demand inventory components.
5
Benefits of MRP
1. Better response to customer orders
2. Faster response to market changes
3. Improved utilization of facilities and labour.
4. Reduced inventory levels
MNT 2012
5Material Requirement Planning (MRP)
MNT 2012
The Planning Process
Figure 14.1
Is capacity plan being
met?
Is execution
meeting the plan?
Change master
production schedule?
Change capacity?
Change requirements?
No
Execute material plans
Execute capacity plans
Yes
Realistic?
Capacity requirements plan
Material requirements plan
Master production schedule
5
MNT 2012
Aggregate Production Plan
Months January February
Aggregate Production Plan 1,500 1,200(Shows the totalquantity of amplifiers)
Weeks 1 2 3 4 5 6 7 8
Master Production Schedule(Shows the specific type andquantity of amplifier to beproduced
240-watt amplifier 100 100 100 100
150-watt amplifier 500 500 450 450
75-watt amplifier 300 100
Figure 14.2
5
MNT 2012
Bills of Material
List of components, ingredients, and materials needed to make product
Provides product structure Items above given level are called
parents Items below given level are called
children
5Material Requirement Planning (MRP)
MNT 2012
BOM Example
B(2) Std. 12” Speaker kit C(3)
Std. 12” Speaker kit w/ amp-booster1
E(2)E(2) F(2)
Packing box and installation kit of wire,
bolts, and screws
Std. 12” Speaker booster assembly
2
D(2)
12” Speaker
D(2)
12” Speaker
G(1)
Amp-booster
3
Product structure for “Awesome” (A)
A
Level
0
MNT 2012
BOM Example
B(2) Std. 12” Speaker kit C(3)
Std. 12” Speaker kit w/ amp-booster1
E(2)E(2) F(2)
Packing box and installation kit of wire,
bolts, and screws
Std. 12” Speaker booster assembly
2
D(2)
12” Speaker
D(2)
12” Speaker
G(1)
Amp-booster
3
Product structure for “Awesome” (A)
A
Level
0
Part B: 2 x number of As = (2)(50) = 100Part C: 3 x number of As = (3)(50) = 150Part D: 2 x number of Bs
+ 2 x number of Fs = (2)(100) + (2)(300) = 800Part E: 2 x number of Bs
+ 2 x number of Cs = (2)(100) + (2)(150) = 500Part F: 2 x number of Cs = (2)(150) = 300Part G: 1 x number of Fs = (1)(300) = 300
5
MNT 2012
MRP Structure
Figure 14.5
Output Reports
MRP by period report
MRP by date report
Planned order report
Purchase advice
Exception reports
Order early or late or not needed
Order quantity too small or too large
Data Files
Purchasing data
BOM
Lead times
(Item master file)
Inventory data
Masterproduction schedule
Material requirement
planning programs
(computer and software)
5
MNT 2012
Determining Gross Requirements
Starts with a production schedule for the end item – 50 units of Item A in week 8
Using the lead time for the item, determine the week in which the order should be released – a 1 week lead time means the order for 50 units should be released in week 7
This step is often called “lead time offset” or “time phasing”
5
MNT 2012
Determining Gross Requirements
From the BOM, every Item A requires 2 Item Bs – 100 Item Bs are required in week 7 to satisfy the order release for Item A
The lead time for the Item B is 2 weeks – release an order for 100 units of Item B in week 5
The timing and quantity for component requirements are determined by the order release of the parent(s)
5
MNT 2012
Determining Gross Requirements
The process continues through the entire BOM one level at a time – often called “explosion”
By processing the BOM by level, items with multiple parents are only processed once, saving time and resources and reducing confusion
Low-level coding ensures that each item appears at only one level in the BOM
5
MNT 2012
Gross Requirements Plan
Table 14.3
Week
1 2 3 4 5 6 7 8 Lead Time
A. Required date 50Order release date 50 1 week
B. Required date 100Order release date 100 2 weeks
C. Required date 150Order release date 150 1 week
E. Required date 200 300Order release date 200 300 2 weeks
F. Required date 300Order release date 300 3 weeks
G. Required date 600 200Order release date 600 200 1 week
G. Required date 300Order release date 300 2 weeks
5
MNT 2012
Net Requirements Plan
MNT 2012
Net Requirements Plan
MNT 2012
Determining Net Requirements
Starts with a production schedule for the end item – 50 units of Item A in week 8
Because there are 10 Item As on hand, only 40 are actually required – (net requirement) = (gross requirement - on- hand inventory)
The planned order receipt for Item A in week 8 is 40 units – 40 = 50 - 10
5
MNT 2012
Determining Net Requirements
Following the lead time offset procedure, the planned order release for Item A is now 40 units in week 7
The gross requirement for Item B is now 80 units in week 7
There are 15 units of Item B on hand, so the net requirement is 65 units in week 7
A planned order receipt of 65 units in week 7 generates a planned order release of 65 units in week 5
5
MNT 2012
Determining Net Requirements
A planned order receipt of 65 units in week 7 generates a planned order release of 65 units in week 5
The on-hand inventory record for Item B is updated to reflect the use of the 15 items in inventory and shows no on-hand inventory in week 8
This is referred to as the Gross-to-Net calculation and is the third basic function of the MRP process
MNT 2012
S
B C
12 138 9 10 11
20 3040
Lead time = 6 for SMaster schedule for S
Gross Requirements Schedule
Figure 14.6
1 2 3
10 10
Master schedulefor B
sold directly
Periods
Therefore, these are the gross requirements for B
Gross requirements: B 10 40 50 2040+10 15+30=50 =45
1 2 3 4 5 6 7 8Periods
A
B C
Lead time = 4 for AMaster schedule for A
5 6 7 8 9 10 11
40 1550
5
MNT 2012
Net Requirements Plan
The logic of net requirements
Available inventory
Net requirementsOn hand
Scheduled receipts+– =
Total requirements
Gross requirements Allocations+
5
MNT 2012
MRP Planning Sheet
Figure 14.7
5
MNT 2012
Safety Stock
BOMs, inventory records, purchase and production quantities may not be perfect
Consideration of safety stock may be prudentShould be minimized and ultimately
eliminatedTypically built into projected on-hand
inventory
5
MNT 2012
MRP Management
MRP is a dynamic system Facilitates replanning when changes occur
Regenerating Net change
System nervousness can result from too many changes
Time fences put limits on replanning Pegging links each item to its parent
allowing effective analysis of changes
5
MNT 2012
MRP and JIT
MRP is a planning system that does not do detailed scheduling
MRP requires fixed lead times which might actually vary with batch size
JIT excels at rapidly moving small batches of material through the system
5
MNT 2012
Lot-Sizing Techniques
Lot-for-lot techniques order just what is required for production based on net requirements May not always be feasible If setup costs are high, lot-for-lot can
be expensive
Economic order quantity (EOQ) EOQ expects a known constant
demand and MRP systems often deal with unknown and variable demand
5
MNT 2012
Lot-Sizing Techniques
Part Period Balancing (PPB) looks at future orders to determine most economic lot size
The Wagner-Whitin algorithm is a complex dynamic programming technique Assumes a finite time horizon Effective, but computationally
burdensome
5
MNT 2012
Lot-for-Lot Example
1 2 3 4 5 6 7 8 9 10
Gross requirements 35 30 40 0 10 40 30 0 30 55
Scheduled receipts
Projected on hand 35 35 0 0 0 0 0 0 0 0 0
Net requirements 0 30 40 0 10 40 30 0 30 55
Planned order receipts 30 40 10 40 30 30 55
Planned order releases 30 40 10 40 30 30 55
Holding cost = $1/week; Setup cost = $100; Lead time = 1 week
5
MNT 2012
Lot-for-Lot Example
1 2 3 4 5 6 7 8 9 10
Gross requirements 35 30 40 0 10 40 30 0 30 55
Scheduled receipts
Projected on hand 35 35 0 0 0 0 0 0 0 0 0
Net requirements 0 30 40 0 10 40 30 0 30 55
Planned order receipts 30 40 10 40 30 30 55
Planned order releases 30 40 10 40 30 30 55
Holding cost = $1/week; Setup cost = $100; Lead time = 1 week
No on-hand inventory is carried through the systemTotal holding cost = $0
There are seven setups for this item in this planTotal ordering cost = 7 x $100 = $700
5
MNT 2012
EOQ Lot Size Example
1 2 3 4 5 6 7 8 9 10
Gross requirements 35 30 40 0 10 40 30 0 30 55
Scheduled receipts
Projected on hand 35 35 0 43 3 3 66 26 69 69 39
Net requirements 0 30 0 0 7 0 4 0 0 16
Planned order receipts 73 73 73 73
Planned order releases 73 73 73 73
Holding cost = $1/week; Setup cost = $100; Lead time = 1 week
Average weekly gross requirements = 27; EOQ = 73 units
5
MNT 2012
EOQ Lot Size Example
1 2 3 4 5 6 7 8 9 10
Gross requirements 35 30 40 0 10 40 30 0 30 55
Scheduled receipts
Projected on hand 35 35 0 0 0 0 0 0 0 0 0
Net requirements 0 30 0 0 7 0 4 0 0 16
Planned order receipts 73 73 73 73
Planned order releases 73 73 73 73
Holding cost = $1/week; Setup cost = $100; Lead time = 1 weekAverage weekly gross requirements = 27; EOQ = 73 units
Annual demand = 1,404Total cost = setup cost + holding costTotal cost = (1,404/73) x $100 + (73/2) x ($1 x 52 weeks)Total cost = $3,798Cost for 10 weeks = $3,798 x (10 weeks/52 weeks) = $730
5
MNT 2012
PPB Example
1 2 3 4 5 6 7 8 9 10
Gross requirements 35 30 40 0 10 40 30 0 30 55
Scheduled receipts
Projected on hand 35
Net requirements
Planned order receipts
Planned order releases
Holding cost = $1/week; Setup cost = $100; Lead time = 1 weekEPP = 100 units
5
MNT 2012
PPB Example
1 2 3 4 5 6 7 8 9 10
Gross requirements 35 30 40 0 10 40 30 0 30 55
Scheduled receipts
Projected on hand 35
Net requirements
Planned order receipts
Planned order releases
Holding cost = $1/week; Setup cost = $100;EPP = 100 units
2 30 02, 3 70 40 = 40 x 12, 3, 4 70 402, 3, 4, 5 80 70 = 40 x 1 + 10 x 3 100 70 1702, 3, 4, 5, 6 120 230 = 40 x 1 + 10 x 3
+ 40 x 4
+ =
Combine periods 2 - 5 as this results in the Part Period closest to the EPP
Combine periods 6 - 9 as this results in the Part Period closest to the EPP
6 40 06, 7 70 30 = 30 x 16, 7, 8 70 30 = 30 x 1 + 0 x 26, 7, 8, 9 100 120 = 30 x 1 + 30 x 3 100 120 220+ =
10 55 0 100 0 100Total cost 300 190 490
+ =+ =
Trial Lot SizePeriods (cumulative net Costs
Combined requirements) Part Periods Setup Holding Total
MNT 2012
PPB Example
1 2 3 4 5 6 7 8 9 10
Gross requirements 35 30 40 0 10 40 30 0 30 55
Scheduled receipts
Projected on hand 35 35 0 50 10 10 0 60 30 30 0
Net requirements 0 30 0 0 0 40 0 0 0 55
Planned order receipts 80 100 55
Planned order releases 80 100 55
Holding cost = $1/week; Setup cost = $100; Lead time = 1 weekEPP = 100 units
5
MNT 2012
Lot-Sizing Summary
For these three examples
Lot-for-lot $700EOQ $730PPB $490
Wagner-Whitin would have yielded a
plan with a total cost of $455
5
MNT 2012
Lot-Sizing Summary
In theory, lot sizes should be recomputed whenever there is a lot size or order quantity change
In practice, this results in system nervousness and instability
Lot-for-lot should be used when low-cost JIT can be achieved
MNT 2012
Lot-Sizing Summary
Lot sizes can be modified to allow for scrap, process constraints, and purchase lots
Use lot-sizing with care as it can cause considerable distortion of requirements at lower levels of the BOM
When setup costs are significant and demand is reasonably smooth, PPB, Wagner-Whitin, or EOQ should give reasonable results
MNT 2012
Extensions of MRP
MRP II Closed-Loop MRP
MRP system provides input to the capacity plan, MPS, and production planning process
Capacity Planning MRP system generates a load report which details capacity
requirements This is used to drive the capacity planning process Changes pass back through the MRP system for
rescheduling
5
MNT 2012
MRP in Services
Some services or service items are directly linked to demand for other services
These can be treated as dependent demand services or items Restaurants Hospitals Hotels
5