Inventory ManagementBasic EOQ Model 1. Demand is known, constant, and independent 2. Lead time is...
Transcript of Inventory ManagementBasic EOQ Model 1. Demand is known, constant, and independent 2. Lead time is...
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12 - 1Copyright © 2017 Pearson Education, Inc.
PowerPoint presentation to accompany
Heizer, Render, Munson
Operations Management, Twelfth Edition
Principles of Operations Management, Tenth Edition
PowerPoint slides by Jeff Heyl
Inventory Management 12
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12 - 2Copyright © 2017 Pearson Education, Inc.
Inventory Models for
Independent Demand
Need to determine when and how much to order
1. Basic economic order quantity (EOQ) model
2. Production order quantity model
3. Quantity discount model
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12 - 3Copyright © 2017 Pearson Education, Inc.
Basic EOQ Model
1. Demand is known, constant, and independent
2. Lead time is known and constant
3. Receipt of inventory is instantaneous and complete
4. Quantity discounts are not possible
5. Only variable costs are setup (or ordering) and holding
6. Stockouts can be completely avoided
Important assumptions
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12 - 4Copyright © 2017 Pearson Education, Inc.
Inventory Usage Over Time
Figure 12.3
Order quantity = Q(maximum inventory
level)
Usage rate
Average inventory on hand
Q
2
Minimum inventory
Inve
nto
ry le
ve
l
Time0
Total order received
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12 - 5Copyright © 2017 Pearson Education, Inc.
Minimizing CostsObjective is to minimize total costs
Table 12.4(c)
Annual cost
Order quantity
Total cost of holding and setup (order)
Holding cost
Setup (order) cost
Minimum total cost
Optimal order quantity (Q*)
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12 - 6Copyright © 2017 Pearson Education, Inc.
Minimizing Costs
▶ By minimizing the sum of setup (or ordering) and holding costs, total costs are minimized
▶ Optimal order size Q* will minimize total cost
▶ A reduction in either cost reduces the total cost
▶ Optimal order quantity occurs when holding cost and setup cost are equal
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12 - 7Copyright © 2017 Pearson Education, Inc.
Minimizing Costs
Q = Number of units per order
Q* = Optimal number of units per order (EOQ)
D = Annual demand in units for the inventory item
S = Setup or ordering cost for each order
H = Holding or carrying cost per unit per year
Annual setup cost = (Number of orders placed per year)
x (Setup or order cost per order)
Annual demand
Number of units in each orderSetup or order
cost per order=
= D
Q
æ
èç
ö
ø÷S
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12 - 8Copyright © 2017 Pearson Education, Inc.
Minimizing Costs
Annual setup cost = (Number of orders placed per year)
x (Setup or order cost per order)
Annual demand
Number of units in each orderSetup or order
cost per order=
= D
Q
æ
èç
ö
ø÷S
Q = Number of pieces per order
Q* = Optimal number of pieces per order (EOQ)
D = Annual demand in units for the inventory item
S = Setup or ordering cost for each order
H = Holding or carrying cost per unit per year
Annual setup cost = D
QS
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Q = Number of pieces per order
Q* = Optimal number of pieces per order (EOQ)
D = Annual demand in units for the inventory item
S = Setup or ordering cost for each order
H = Holding or carrying cost per unit per year
Minimizing Costs
Annual holding cost = (Average inventory level)
x (Holding cost per unit per year)
Order quantity
2(Holding cost per unit per year)=
= Q
2
æ
èç
ö
ø÷H
Annual setup cost = D
QS
Annual holding cost = Q
2H
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12 - 10Copyright © 2017 Pearson Education, Inc.
Minimizing Costs
D
Q
æ
èç
ö
ø÷S =
Q
2
æ
èç
ö
ø÷H
Optimal order quantity is found when annual setup cost equals annual holding cost
Solving for Q* 2DS =Q2H
Q2 =2DS
H
Q* =2DS
H
Q = Number of pieces per order
Q* = Optimal number of pieces per order (EOQ)
D = Annual demand in units for the inventory item
S = Setup or ordering cost for each order
H = Holding or carrying cost per unit per year
Annual setup cost = D
QS
Annual holding cost = Q
2H
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12 - 11Copyright © 2017 Pearson Education, Inc.
An EOQ Example
Determine optimal number of needles to order
D = 1,000 units
S = $10 per order
H = $.50 per unit per year
Q* =2DS
H
Q* =2(1,000)(10)
0.50= 40,000 = 200 units
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12 - 12Copyright © 2017 Pearson Education, Inc.
An EOQ Example
Determine expected number of orders
D = 1,000 units Q* = 200 units
S = $10 per order
H = $.50 per unit per year
N = = 5 orders per year 1,000
200
= N = =Expected number of
orders
Demand
Order quantity
D
Q*
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12 - 13Copyright © 2017 Pearson Education, Inc.
An EOQ Example
Determine optimal time between orders
D = 1,000 units Q* = 200 units
S = $10 per order N = 5 orders/year
H = $.50 per unit per year
T = = 50 days between orders250
5
= T =Expected
time between orders
Number of working days per year
Expected number of orders
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An EOQ Example
Determine the total annual cost
D = 1,000 units Q* = 200 units
S = $10 per order N = 5 orders/year
H = $.50 per unit per year T = 50 days
Total annual cost = Setup cost + Holding cost
TC =D
QS +Q
2H
=1,000
200($10)+
200
2($.50)
= (5)($10)+ (100)($.50)
= $50+$50 = $100
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The EOQ Model
When including actual cost of material P
Total annual cost = Setup cost + Holding cost + Product cost
TC =D
QS +Q
2H + PD
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Robust Model
▶ The EOQ model is robust
▶ It works even if all parameters and assumptions are not met
▶ The total cost curve is relatively flat in the area of the EOQ
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An EOQ Example
Determine optimal number of needles to order
D = 1,000 units Q*1,000 = 200 units
S = $10 per order T = 50 days
H = $.50 per unit per year
N= 5 orders/year
TC =D
QS +Q
2H
=1,500
200($10)+
200
2($.50)
= $75+$50 = $125
1,500 units
=1,500
244.9($10)+
244.9
2($.50)
= 6.125($10)+122.45($.50)
= $61.25+$61.22 = $122.47
Q*1,500 = 244.9 units
Ordering old Q* Ordering new Q*
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12 - 18Copyright © 2017 Pearson Education, Inc.
Ordering new Q*
TC =D
QS +Q
2H
=1,500
200($10)+
200
2($.50)
= $75+$50 = $125
=1,500
244.9($10)+
244.9
2($.50)
= 6.125($10)+122.45($.50)
= $61.25+$61.22 = $122.47
Ordering old Q*
Q*1,500 = 244.9 units
An EOQ Example
Determine optimal number of needles to order
D = 1,000 units Q*1,000 = 200 units
S = $10 per order T = 50 days
H = $.50 per unit per year
N= 5 orders/year
1,500 units Only 2% less than the total cost of $125 when the
order quantity was 200
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12 - 19Copyright © 2017 Pearson Education, Inc.
Reorder Points▶ EOQ answers the “how much” question
▶ The reorder point (ROP) tells “when” to order
▶ Lead time (L) is the time between placing and receiving an order
ROP =Lead time for a new
order in daysDemand per day
ROP = d x L
d = D
Number of working days in a year
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Reorder Point Curve
Q*
ROP (units)
Invento
ry level (u
nits)
Time (days)
Figure 12.5
Lead time = L
Slope = units/day = d
Stock is replenished as order arrives
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Reorder Point ExampleDemand = 8,000 iPhones per year
250 working day year
Lead time for orders is 3 working days, may take 4
ROP = d x L
d = D
Number of working days in a year
= 8,000/250 = 32 units
= 32 units per day x 3 days = 96 units
= 32 units per day x 4 days = 128 units
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12 - 22Copyright © 2017 Pearson Education, Inc.
Production Order Quantity Model
1. Used when inventory builds up over a period of time after an order is placed
2. Used when units are produced and sold simultaneously
Invento
ry level
Time
Demand part of cycle with no production (only usage takes place)
Part of inventory cycle during which production (and usage) is taking place
t
Maximum inventory
Figure 12.6
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12 - 23Copyright © 2017 Pearson Education, Inc.
Production Order Quantity Model
Q = Number of units per order p = Daily production rate
H = Holding cost per unit per year d = Daily demand/usage rate
t = Length of the production run in days
= (Average inventory level) xAnnual inventory holding cost
Holding cost per unit per year
= (Maximum inventory level)/2Annual inventory level
= –Maximum inventory level
Total produced during the production run
Total used during the production run
= pt – dt
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12 - 24Copyright © 2017 Pearson Education, Inc.
Production Order Quantity Model
Q = Number of units per order p = Daily production rate
H = Holding cost per unit per year d = Daily demand/usage rate
t = Length of the production run in days
= –Maximum inventory level
Total produced during the production run
Total used during the production run
= pt – dt
However, Q = total produced = pt ; thus t = Q/p
Maximum inventory level = p – d = Q 1 –
Q
p
Q
pd
p
Holding cost = (H) = 1 – Hd
p
Q
2
Maximum inventory level
2
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12 - 25Copyright © 2017 Pearson Education, Inc.
Production Order Quantity Model
Q = Number of units per order p = Daily production rate
H = Holding cost per unit per year d = Daily demand/usage rate
t = Length of the production run in days
Setup cost = (D /Q)S
Holding cost = 12HQ 1- d p( )é
ëùû
D
QS = 1
2HQ 1- d p( )é
ëùû
Q2 =2DS
H 1- d p( )éë
ùû
Qp
* =2DS
H 1- d p( )éë
ùû
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Production Order Quantity
Example
D = 1,000 units p = 8 units per day
S = $10 d = 4 units per day
H = $0.50 per unit per year
Qp
* =2DS
H 1- d p( )éë
ùû
Qp
* =2(1,000)(10)
0.50 1- (4 8)éë
ùû
=20,000
0.50(1 2)= 80,000
= 282.8 hubcaps, or 283 hubcaps
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12 - 27Copyright © 2017 Pearson Education, Inc.
Production Order Quantity Model
When annual data are used the equation becomes:
Note:
d = 4 = =D
Number of days the plant is in operation
1,000
250
Qp
* =2DS
H 1-Annual demand rate
Annual production rate
æ
èç
ö
ø÷
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12 - 28Copyright © 2017 Pearson Education, Inc.
Quantity Discount Models
▶ Reduced prices are often available when larger quantities are purchased
▶ Trade-off is between reduced product cost and increased holding cost
TABLE 12.2 A Quantity Discount Schedule
PRICE RANGE QUANTITY ORDERED PRICE PER UNIT P
Initial price 0 to 119 $100
Discount price 1 200 to 1,499 $ 98
Discount price 2 1,500 and over $ 96
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12 - 29Copyright © 2017 Pearson Education, Inc.
Quantity Discount Models
Q* =2DS
IP
Total annual cost = Setup cost + Holding cost + Product cost
TC =D
QS +Q
2IP+PD
where Q = Quantity ordered P = Price per unit
D = Annual demand in units I = Holding cost per unit per year
S = Ordering or setup cost per order expressed as a percent of price P
Because unit price varies, holding cost is expressed
as a percent (I) of unit price (P)
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12 - 30Copyright © 2017 Pearson Education, Inc.
Quantity Discount Models
Steps in analyzing a quantity discount
1. Starting with the lowest possible purchase price, calculate Q* until the first feasible EOQ is found. This is a possible best order quantity, along with all price-break quantities for all lower prices.
2. Calculate the total annual cost for each possible order quantity determined in Step 1. Select the quantity that gives the lowest total cost.
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12 - 31Copyright © 2017 Pearson Education, Inc.
Quantity Discount ModelsFigure 12.7
520,053 –517,155 –
Annu
al Tota
l C
ost
Order Quantity
550,000 –
540,000 –
530,000 –
510,000 –
500,000 –
120 1,500
TC for No Discount
TC for Discount 2
TC for Discount 1
Initial Price Discount Price 1 Discount Price 2
Possible Order
Quantities
Not Feasible
Not Feasible
Feasible
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12 - 32Copyright © 2017 Pearson Education, Inc.
Quantity Discount Example
Calculate Q* for every discount starting with the lowest price
Q* =2DS
IP
Q$96* = = 278 drones/order2(5,200)($200)
(.28)($96)
Q$98* = = 275 drones/order2(5,200)($200)
(.28)($98)
Infeasible – calculate Q*
for next-higher price
Feasible
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12 - 33Copyright © 2017 Pearson Education, Inc.
Quantity Discount Example
TABLE 12.3 Total Cost Computations for Chris Beehner Electronics
ORDER QUANTITY
UNIT PRICE
ANNUAL ORDERING
COST
ANNUAL HOLDING
COST
ANNUAL PRODUCT
COSTTOTAL ANNUAL
COST
275 $98 $3,782 $3,773 $509,600 $517,155
1,500 $96 $693 $20,160 $499,200 $520,053
Choose the price and quantity that gives the lowest total cost
Buy 275 drones at $98 per unit
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12 - 34Copyright © 2017 Pearson Education, Inc.
Quantity Discount Variations
▶ All-units discount is the most popular form
▶ Incremental quantity discounts apply only to those units purchased beyond the price break quantity
▶ Fixed fees may encourage larger purchases
▶ Aggregation over items or time
▶ Truckload discounts, buy-one-get-one-free offers, one-time-only sales
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Probabilistic Models and
Safety Stock
▶ Used when demand is not constant or certain
▶ Use safety stock to achieve a desired service level and avoid stockouts
ROP = d x L + ss
Annual stockout costs = The sum of the units short
for each demand level x The probability of that
demand level x The stockout cost/unit
x The number of orders per year
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Safety Stock Example
NUMBER OF UNITS PROBABILITY
30 .2
40 .2
ROP 50 .3
60 .2
70 .1
1.0
ROP = 50 units Stockout cost = $40 per frame
Orders per year = 6 Carrying cost = $5 per frame per year
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Safety Stock Example
ROP = 50 units Stockout cost = $40 per frame
Orders per year = 6 Carrying cost = $5 per frame per year
SAFETY STOCK
ADDITIONAL HOLDING COST STOCKOUT COST
TOTAL COST
20 (20)($5) = $100 $0 $100
10 (10)($5) = $ 50 (10)(.1)($40)(6) = $240 $290
0 $ 0 (10)(.2)($40)(6) + (20)(.1)($40)(6) = $960 $960
A safety stock of 20 frames gives the lowest total cost
ROP = 50 + 20 = 70 frames
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Safety stock 16.5 units
ROP
Place order
Probabilistic DemandIn
vento
ry level
Time0
Minimum demand during lead time
Maximum demand during lead time
Mean demand during lead time
Normal distribution probability of demand during lead time
Expected demand during lead time (350 kits)
ROP = 350 + safety stock of 16.5 = 366.5
Receive order
Lead time
Figure 12.8
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12 - 39Copyright © 2017 Pearson Education, Inc.
Probabilistic Demand
Use prescribed service levels to set safety stock when the cost of stockouts cannot be determined
ROP = demand during lead time + ZsdLT
where Z = Number of standard deviations
sdLT = Standard deviation of demand during lead time
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12 - 40Copyright © 2017 Pearson Education, Inc.
Probabilistic Demand
Safety stock
Probability ofno stockout
95% of the time
Mean demand
350
ROP = ? kits Quantity
Number of standard deviations
0 z
Risk of a stockout (5% of area of normal curve)
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12 - 41Copyright © 2017 Pearson Education, Inc.
Probabilistic Examplem = Average demand = 350 kits
sdLT = Standard deviation of demand during lead time = 10 kits
Stockout policy = 5% (service level = 95%)
Using Appendix I, for an area under the curve of
95%, the Z = 1.645
Safety stock = ZsdLT = 1.645(10) = 16.5 kits
Reorder point = Expected demand during lead time + Safety stock
= 350 kits + 16.5 kits of safety stock
= 366.5 or 367 kits
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12 - 42Copyright © 2017 Pearson Education, Inc.
Other Probabilistic Models
▶When data on demand during lead time is not available, there are other models available
1. When demand is variable and lead time is constant
2. When lead time is variable and demand is constant
3. When both demand and lead time are variable
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12 - 43Copyright © 2017 Pearson Education, Inc.
Other Probabilistic Models
Demand is variable and lead time is constant
ROP = (Average daily demand
x Lead time in days) + ZsdLT
where sdLT = sd Lead time
sd = Standard deviation of demand per day
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12 - 44Copyright © 2017 Pearson Education, Inc.
Probabilistic Example
Average daily demand (normally distributed) = 15
Lead time in days (constant) = 2
Standard deviation of daily demand = 5
Service level = 90% Z for 90% = 1.28From Appendix I
ROP = (15 units x 2 days) + ZsdLT
= 30 + 1.28(5)( 2)
= 30 + 9.02 = 39.02 ≈ 39
Safety stock is about 9 computers
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12 - 45Copyright © 2017 Pearson Education, Inc.
Other Probabilistic Models
Lead time is variable and demand is constant
ROP = (Daily demand x Average lead time
in days) + Z x (Daily demand) x sLT
where sLT = Standard deviation of lead time in days
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12 - 46Copyright © 2017 Pearson Education, Inc.
Probabilistic Example
Daily demand (constant) = 10
Average lead time = 6 days
Standard deviation of lead time = sLT = 1
Service level = 98%, so Z (from Appendix I) = 2.055
ROP = (10 units x 6 days) + 2.055(10 units)(1)
= 60 + 20.55 = 80.55
Reorder point is about 81 cameras
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12 - 47Copyright © 2017 Pearson Education, Inc.
Other Probabilistic Models
Both demand and lead time are variable
ROP = (Average daily demand
x Average lead time) + ZsdLT
where sd = Standard deviation of demand per day
sLT = Standard deviation of lead time in days
sdLT = (Average lead time x sd2)
+ (Average daily demand)2s2LT
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12 - 48Copyright © 2017 Pearson Education, Inc.
Probabilistic Example
Average daily demand (normally distributed) = 150
Standard deviation = sd = 16
Average lead time 5 days (normally distributed)
Standard deviation = sLT = 1 day
Service level = 95%, so Z = 1.645 (from Appendix I)
ROP= (150packs´5days)+1.645sdLT
sdLT
= 5days´162( )+ 1502 ´12( ) = 5´256( )+ 22,500´1( )
= 1,280( )+ 22,500( ) = 23,780 @154
ROP= (150´5)+1.645(154)@750+253=1,003packs
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12 - 49Copyright © 2017 Pearson Education, Inc.
Single-Period Model
▶ Only one order is placed for a product
▶ Units have little or no value at the end of the sales period
Cs = Cost of shortage = Sales price/unit – Cost/unit
Co = Cost of overage = Cost/unit – Salvage value
Service level =Cs
Cs + Co
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12 - 50Copyright © 2017 Pearson Education, Inc.
Single-Period Example
Average demand = m = 120 papers/day
Standard deviation = s = 15 papers
Cs = cost of shortage = $1.25 – $.70 = $.55
Co = cost of overage = $.70 – $.30 = $.40
Service level = Cs
Cs + Co
=
= = .579
.55
.55 + .40
.55
.95
Service level
57.9%
Optimal stocking level
m = 120
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12 - 51Copyright © 2017 Pearson Education, Inc.
Single-Period Example
From Appendix I, for the area .579, Z .20
The optimal stocking level
= 120 copies + (.20)(s)
= 120 + (.20)(15) = 120 + 3 = 123 papers
The stockout risk = 1 – Service level
= 1 – .579 = .422 = 42.2%
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12 - 52Copyright © 2017 Pearson Education, Inc.
Fixed-Period (P) Systems
▶ Fixed-quantity models require continuous monitoring using perpetual inventory systems
▶ In fixed-period systems orders placed at the end of a fixed period
▶ Periodic review, P system
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12 - 53Copyright © 2017 Pearson Education, Inc.
Fixed-Period (P) Systems
▶ Inventory counted only at end of period
▶ Order brings inventory up to target level
▶Only relevant costs are ordering and holding
▶ Lead times are known and constant
▶ Items are independent of one another
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12 - 54Copyright © 2017 Pearson Education, Inc.
Fixed-Period (P) SystemsO
n-h
and invento
ry
Time
Q1
Q2
Target quantity (T)
P
Q3
Q4
P
P
Figure 12.9
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12 - 55Copyright © 2017 Pearson Education, Inc.
Fixed-Period Systems
▶ Inventory is only counted at each review period
▶May be scheduled at convenient times
▶ Appropriate in routine situations
▶May result in stockouts between periods
▶May require increased safety stock
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12 - 56Copyright © 2017 Pearson Education, Inc.
All rights reserved. No part of this publication may be reproduced, stored in a
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Printed in the United States of America.