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Stock CUST016
Stock CUST016
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Functions of Inventory.
[Coyle, pp186-281]
Inventory Functions.
Safety Stock.
․ Fluctuation stock is a cushion of protection against uncertainty in the demand
or in the replenishment lead time.
․ On the demand or customer side, there is usually uncertainty about how much
customer will buy and when. Forecast demand is a common approach to help
resolve uncertainty, but it is never completely accurate.
․ On the supply side, there may be uncertainty about obtaining what is needed
from vendors or suppliers and about how long it will take for fulfilling of the
order. Uncertainty can arise from transportation in terms of getting reliable
delivery.
- 3 -
Functions of Inventory.
[Coyle, pp186-281]
Inventory Functions.
In-transit and In-process Inventory.
․ The transportation alternatives available for shipping freight may have different
transit time as well as other service level differences, for example, reliability
and damage rates. The longer freight is in transit, the higher the inventory
costs and, probably, the customer service related costs.
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Functions of Inventory.
[Coyle, pp186-281]
Inventory Functions.
Anticipation Stock.
․ Seasonality can occur on the inbound side of a company's logistics system or
the outbound side or both. Usually, companies that are faced with seasonality
of supply and/or demand need to carefully analyze how much inventory they
should accumulate.
- 5 -
Functions of Inventory.
[Coyle, pp186-281]
Inventory Functions.
Hedging Stock.
․ A fifth reason for inventory arise when companies anticipate some unusual
event, for example, strike, significant price increase, a major shortage of supply
due to weather or political unrest, and so on. In such situations, companies
may accumulate inventory to "hedge" against the unique event. Again, an
analysis should be undertaken to assess the risk, probability, and cost of the
inventory.
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Inventory Cost.
[Coyle, pp186-281]
Inventory Carrying Cost.
Capital cost.
․ Sometimes called the interest or opportunity cost, this cost type focuses upon
what having capital tied up in inventory costs a company. The capital cost is
frequently the largest component of inventory carrying cost.
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Inventory Cost.
[Coyle, pp186-281]
Inventory Carrying Cost.
Inventory Risk Cost.
․ This final major component of inventory carrying cost reflects the very real
possibility that inventory dollar value may decline for reasons largely corporate
control.
․ Any calculation of inventory risk costs should include the costs associated
with obsolescence, demage, pilferage, theft, and other risks to inventoried
product. The extent to which inventoried items are subject to such risks will
affect the inventory value and thus the carrying costs.
- 8 -
Inventory Cost.
[Coyle, pp186-281]
Calculating Inventory Carrying Cost.
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Inventory Cost.
[Coyle, pp186-281]
Order/Setup Cost.
Order Cost.
․ The costs associated with ordering or acquiring inventory have both fixed and
variable components. The fixed element may refer to the cost of the
information system, facilities, and technology available to facilitate
order-placement activities. This fixed cost remains constant in relation to the
number of orders placed.
․ Some of the types of activities that may be responsible for these costs include
: (1) reviewing inventory stock levels, (2) preparing and processing order
requisitions or purchasing orders, (3) preparing and processing receiving
reports, (4) checking and inspecting stock prior to placement in inventory, and
(5) preparing and processing payment.
- 10 -
Inventory Cost.
[Coyle, pp186-281]
Order/Setup Cost.
Setup Cost.
․ Production setup costs may be more obvious than ordering or acquisition
costs. Setup costs are expense incurred each time a company modifies a
production line to produce a different item for inventory.
․ The fixed portion of setup cost might include use of the capital equipment
needed to change over production facilities, while the variable expense might
include the personnel costs incurred in the process of modifying or changing
the production line.
- 11 -
Inventory Cost.
[Coyle, pp186-281]
Order/Setup Cost and Order Frequency.
No. of Orders Total Annual Inventory
Order Period
per year Carrying Cost
1 week 52 $ 10,400
2 week 26 5,200
4 week 13 2,600
13 week 4 800
26 week 2 400
52 week 1 200
- 12 -
Inventory Cost.
[Coyle, pp186-281]
Inventory Cost Relationship.
- 13 -
Inventory Classification.
[Coyle, pp186-281]
ABC Classification.
Pareto's Law, or the "80-20 Rule."
․ Actually, ABC analysis is rooted in Pareto's law, which separates the "trivial
many" from the "vital few." In inventory terms, this suggests that a relatively
small number of items or stock-keeping units(SKUs) may account for a
considerable impact or value.
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Inventory Visibility.
[Coyle, pp186-281]
Inventory Visibility.
Consideration for Inventory Visibility.
․ Inventory visibility can be interpreted simply as the ability of an organization to
"see" inventory on a real-time basis throughout its logistics and/or supply chain
system.
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Inventory Visibility.
[Coyle, pp186-281]
Inventory Visibility.
Consideration for Inventory Visibility.
․ Keeping inventory visible in the supply chain is a special challenge. Essentially,
what is required is :
- Tracking and tracing inventory status at the SKU/line item detail level for all
order.
- Providing summary and detailed reports of shipments, orders, products,
transportation equipment, location, and trade lane activity.
- Notification of failures and potential delays in the flow of inventory throughout
the system.
- 16 -
Inventory Visibility.
[Coyle, pp186-281]
Inventory Visibility.
Benefits for Inventory Visibility.
․ Improved customer service through on-time deliveries of complete order to
customer with visibility into order at all stages of the supply chain.
- 17 -
Inventory Visibility.
[Coyle, pp186-281]
Inventory Visibility.
Benefits for Inventory Visibility.
․ Improved cash-to-cash and/or order-to-cash cycle by faster flow of inventory
through the supply chain and by faster order fulfillment.
․ Ability to proactively respond and facilitate service recovery when delays and/or
stockouts are probable by making adjustment in the system and responding
quickly to service demands.
- 18 -
Inventory Performance.
[Coyle, pp186-281]
Inventory Performance Measures.
Customer Service.
․ The first question to raise is whether the company's customer are satisfied
with existing levels of customer service.
- How frequently a need for back ordering or expediting occurs ?
․ The more frequently these occur, the less effective an inventory system is
presumed to be.
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Inventory Performance.
[Coyle, pp186-281]
Inventory Performance Measures.
Inventory Investment.
․ The second question involves inventory turnover measures calculated for an
entire product line and for individual products and product groping.
․ Inventory turnover, sometimes referred to as inventory velocity, is calculated by
dividing annual sales in dollars by average inventory measured in dollars.
Cost of Goods Sold
Inventory Turns =
Average Inventory
․ Assuming that the inventory valuation bases are equivalent (e.g., both are
valued in terms of retail price or cost of goods sold), the resulting figure
measures how many times per year average inventory turns over.
- 20 -
Inventory Performance.
[Coyle, pp186-281]
Inventory Performance Measures.
Source : Cass Information Services and The Ohio State University, 1993.
- 21 -
Inventory Planning.
[Coyle, pp186-281]
Fixed Order Quantity : EOQ.
The principal assumptions of the simple EOQ model.
1. A continuous, constant, and known demand rate.
2. A constant and known replenishment or lead time.
3. The satisfaction of all demand.
4. A constant price or cost that is independent of the order quantity or time.
(e.g., purchase price or transport cost)
5. No inventory in transit.
6. One item of inventory or no interaction between items.
7. Infinite planning horizon.
8. No limit on capital availability.
- 22 -
Inventory Planning.
[Coyle, pp186-281]
Fixed Order Quantity : EOQ.
Calculating EOQ.
2×A×S
Economic Order Quantity (EOQ) = C×i
- 23 -
Inventory Planning.
[Coyle, pp186-281]
The Condition of Uncertainty.
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Inventory Planning.
[Coyle, pp186-281]
The Condition of Uncertainty.
Demand Variations.
․ First, customers usually purchase products somewhat sporadically. The usage
rates of many items vary depending on weather, social needs, psychological
needs, and a whole host of other factors. As a results, sales of most items
vary day by day, week by week, or season by season.
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Inventory Planning.
[Coyle, pp186-281]
The Condition of Uncertainty.
Uncertainty of Demand and LT.
․ If demand and lead time are constant
and known in advance, calculating
reorder point would be easy.
Normal Distribution.
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Inventory Planning.
[Coyle, pp186-281]
Calculating Safety Stock.
Reorder Point and Safety Stock with Uncertainty.
․ ROP = DDLT + SS
․ SS = Service factor × σ
where DDLT is demand during lead time.
/ SS is safety stock.
where σ is standard deviation for demand.
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Inventory Planning.
[Coyle, pp186-281]
Calculating Safety Stock.
Demand and Replenishment Uncertainty.
․ ROP = R ( X LT ) + SS
․ SS = Service Factor × σ
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Inventory Planning.
[Coyle, pp186-281]
Fixed Order Interval Approach.
- 29 -
Additional Approaches.
[Coyle, pp186-281]
Just In Time.
JIT Concept.
․ Generally, JIT systems are designed to manage lead times and to eliminate
waste. Ideally, product should arrive exactly when a firm needs it, with no
tolerance for late or early deliverables. Many JIT systems place a high priority
on short, consistent lead times. This may help to explain the recent popularity
of "quick response" system for inventory.
Move card path. When a container of Production card path. When a container
parts is selected for use from an of parts is picked from an outbound
inbound stockpoint, the move card is stockpoint, the production card is
removed from the container and taken removed and left behind as authorizaton
to the outbound stockpoint of the to make a standard container of parts
preceding work center as authorized to to replace the one taken.
pick another container of parts.
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Additional Approaches.
[Coyle, pp186-281]
Material Requirement Planning.
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Additional Approaches.
[Coyle, pp186-281]
Material Requirement Planning.
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Additional Approaches.
[Coyle, pp186-281]
Distribution Requirement Planning.
DRP Concept.
․ DRP systems are time phased models that include demand forecasts, purchase
orders, and customer orders for a facility.
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Additional Approaches.
[Coyle, pp186-281]
Distribution Requirement Planning.
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Additional Approaches.
[Coyle, pp186-281]
Conceptual Design of Integrated MRP/DRP System .
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Additional Approaches.
[Coyle, pp186-281]
Conceptual Design of Integrated MRP/DRP System .
Benefits of An Integrated Inventory Planning System.
․ The major marketing benefits.
1. Improved service levels that increase on-time deliveries and decrease customer
complaints.
2. Improved and more effective promotional and new-product introduction plans.
3. Improved ability to anticipate shortages so that marketing efforts are not expended on
products with low stock.
4. Improved inventory coordination with other enterprise functions, since DRP facilities a
common set of planning numbers.
5. Enhanced ability to offer customers a coordinated inventory management service.
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Performance Check.
1. What is the impact on the firm when the firm orders smaller quantities on a more
frequent basis ?
Ⅰ. Increased transportation costs.
Ⅱ. Decreased transportation costs.
Ⅲ. Higher ordering costs.
Ⅳ. Reductions in inventory investment.
A. Ⅰ, Ⅲ B. Ⅱ, Ⅲ C. Ⅰ, Ⅲ, Ⅳ D. Ⅱ, Ⅲ, Ⅳ
2. Given the same customer service level, low inventory carrying costs lead to
A. Multiple warehouse. B. Faster modes of transportation.
C. Fewer warehouse. D. None of the above.
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Performance Check.
3. Knowledge of inventory carrying costs is necessary to accurately determine :
A. Lot sizing. B. Lead time.
C. Competitor's revenue and profit margin. D. Storage location practice.
4. Inventory carrying costs should include only those costs that vary with the quantity of
inventory and that can be categorized into which groups :
Ⅰ. Capital costs.
Ⅱ. Material planning cost.
Ⅲ. Inventory risk costs.
Ⅳ. Lost capacity costs.
Ⅴ. Storage space costs.
A. Ⅰ, Ⅱ, Ⅲ B. Ⅰ, Ⅲ, Ⅴ C. Ⅰ, Ⅲ, Ⅳ, Ⅴ D. Ⅰ, Ⅱ, Ⅲ, Ⅳ, Ⅴ
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Performance Check.
5. Which one of the following is NOT a distinct costing alternative under direct costing ?
A. Actual direct costing. B. Standard direct costing.
C. Absorption costing. D. First-in-first-out (FIFO).
7. The company has just negotiated to have all of the electronic components purchased
from a local distributor changed to consignment. Which of the following actions need to
be taken prior to the next receipt for the existing inventory ?
A. Convert the balances to consignment to standardize on the inventory classification.
B. Issue the balances to work in process to zero out raw material inventory.
C. Record the balances as company-owned inventory so costs can be segregated.
D. Reduce the unit costs to zero to eliminate payments to the supplier upon issue.
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Performance Check.
8. ABC classification of inventory is a means to categorize materials in terms of which
of the following ?
A. Function. B. Type.
C. Storage requirements. D. Annual usage value.
9. Which of the following statements is TRUE about reaching a high level inventory
record accuracy ?
A. Inventory levels will usually be reduced
B. Safety stock negates the need to be very accurate
C. The savings would be small and therefore not worth the effort
D. It is difficult to achieve and expensive to maintain
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Performance Check.
10. During inflationary periods, which of the following statements would be true if the
LIFO method of inventory valuation is used ?
A. Inventory value would be lower, cost of goods sold higher
B. Inventory value would be higher, cost of goods sold higher
C. Inventory value would be higher, cost of goods sold lower
D. None of the above
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Performance Check.
12. Which of the following are measures used to control inventory ?
A. Inventory turnover rates.
B. Number of stock-outs resulting form late deliveries.
C. Order fill rate for each suppliers.
D. Variability in order-cycle time for each supplier.
13. A method of inventory control with a focus on waste management : a program from
which to eliminate non-value added activities with the objective of producing high quality
products : "zero-defect", are all definition of :
A. Just-in-Time. B. Kanban.
C. Stockpoint management. D. Total Quality Management.
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Performance Check.
14. Which characteristic is more desirable for controlling production within a pull system ?
A. Flexible capacity
B. Cycle counts
C. Periodic inventory checks
D. Management performance check
15. The process of using planned order releases to calculate gross requirements may
continue on down through the bill of materials for many levels, until one arrives at the
purchase level for every part needed in the manufacturer of a product. This process is
called :
A. Lead-time offset. B. Explosion.
C. Planned order receipt. D. MRP worksheet.
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Performance Check.
16. Investment in inventory is normally justified on basis of all the following, EXCEPT :
A. Minimum stockage at inventory points near market centers, based on the JIT
approach.
B. Provide a hedge against price increase.
C. Provide a buffer against seasonal demands.
D. Promote production efficiency.
17. Stocks for which there have been no demand for a specified period are termed as :
A. Random demand support stocks. B. Speculative stocks.
C. Risk contingency stockage. D. Dead stocks.
- 44 -
Performance Check.
18. Given the following item characteristics :
․ Order placement cost : $50 per order.
․ Annual demand : 300 units.
․ Unit cost : $80 per unit.
․ Inventory carrying rate : 5.0%
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Performance Check.
20. The ABC inventory management approach is applied under all the following
circumstances, EXCEPT :
A. Management of SKUs with high cost values per unit.
B. Management of items with costly storage requirements.
C. Management of items with high rates of sale.
D. When a majority of items indicate predominant cost impact on the corporate
system.
- 46 -
Performance Check.
22. The predominant elements of inventory costs are :
A. Order processing or production set-up, investment, warehousing, plus effects of
inventory risks and stock-out.
B. Carrying rate, annual demand, order cost, item cost.
C. Warehousing, transportation, deterioration, pilferage.
D. Lay-in costs, communication cost, transportation cost, material handling cost.
- 47 -
Performance Check.
24. An inventory item has the following attributes.
․ Order quantity : 75 units.
․ Unit cost : $100.00
․ Ordering cost : $150.00
․ Inventory carrying rate : 5%
․ Annual Demand : 1,000 units.
The annual inventory cost is :
A. $3,950 B. $2,187 C. $5,750 D. $2,375
25. Inventory makes it possible for each of a firms plants to specialize in the products
that it manufactures because :
A. Consolidation warehouses allow the firm to disperse manufacturing by plant location
B. The finished products can be shipped to large mixing warehouses from which
customer orders and products for field warehouses can be shipped
C. Savings in transportation costs.
D. Costs of additional handling are low.
- 48 -
Performance Check.
Solutions :
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
C A A B C A C D A A C A A A B
16 17 18 19 20 21 22 23 24 25
A D C B D C A B B A
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