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Presented by

Neelam Kushwaha

INVENTORY MANAGEMENT

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MEANING OF INVENTORY• The term “ Inventory” is originated from

the French word “ inventaire” and the Latin “inventariom”, which implies a list of thing found.

• The meaning of Inventory is stock of goods.

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INTRODUCTION

Inventory Management occupies the most significant position in the structure of working capital.

Management of inventory may be defined as the sum of total of those activities necessary for the acquisition, storage, disposal or use of materials.

Maintenance of Large size of inventories by a firm required a considerable amount of funds to be invested on them. Efficient and Effective inventory management is necessary in order to avoid unnecessary investment and inadequate investment.

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Components

Of

inventory

Raw

Materials

Work-in-

process

Finished

products

Stores &

spares

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Raw Materials:Raw materials are those inputs that are converted into finished goods through a manufacturing or conversion process. These form a major input for manufacturinga product.Work -in-process:Work-in-process is a stage of stocks between raw materials and finished goods. They represent products that need to under go some other process to become finished goods.Finished products:Finished products are those products, which are completely manufactured and ready for saleStores & spares:Stores & spares inventory (include office and plant cleaning materials like , soap, brooms,, oil , fuel , light, bulbs etc.) are purchased and stored for the purpose of maintenance of machinery.

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Objectives of Inventory Management

• To maintain a large size of inventories of raw material and work-in-process for efficient and smooth production and of finished goods for uninterrupted sales operations.

• To maintain a minimum investment in inventories to maximize profitability.

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AN EFFECTIVE INVENTORY MANAGEMENT SHOULD

ensure a continuous supply of raw materials, to facilitate uninterrupted production

maintain sufficient stocks of raw materials in periods of short supply and anticipate price changes

maintain sufficient finished goods inventory for smooth sales operation, and efficient customer service.

minimize the carrying cost and time, and

control investment in inventories and keep it at an optimum level.

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INVENTORY MANAGEMENT MOTIVES

The Transaction Motive: Transaction motive includes production of goods and sale of goods. Transaction motive facilitates uninterrupted production and delivery of order at a given time (right time).

The Precautionary Motive : This motive necessitates the holding of inventories for unexpected changes in demand and supply factors.

The speculative Motive : This compels to hold some inventories to take the advantage of changes in prices and getting quantity discounts.

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NEED FOR BALANCED INVESTMENT IN INVENTORY

a) Dangers of Excessive (over) Investment in inventory:

• The excessive level of a Inventories consumes funds of the company , they cannot be used for any purpose since they have locked in inventory, and they involve an opportunity costs.

• Carrying excessive inventory over a long- period leads to the loss liquidity . It may not be possible to sell the inventories in times without loss,

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b) Dangers of inadequate Investment in Inventories

• Inadequate raw materials and work- in- progress inventories will disturb production.

• When firm is not able to produce goods without interruption, that leads inadequate of storage of finished goods. If finished goods are not sufficient to meet customer demand, the customers demand, the customer demand, the customers may shift to the competitors, which will lead to loss of customers permanently.

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COSTS OF HOLDING INVENTORIES

Ordering costs: Ordering costs are those costs that are associated with the acquisition of raw materials. In other words The costs that are spend from placing an order to raw materials to the receipt of raw materials.

Inventory carrying costs: Inventory carrying costs are those costs, which are associated in carrying or maintaining inventory.

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RISKS OF HOLDING INVENTORY

Price Decline:

Product Deterioration:

Product Obsolescence:

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Inventory management ensures an adequate supply of materials and stores , minimizes stock outs and shortages and avoids costly interruptions in operations.

It keeps down investment in inventories; inventory carrying costs, and obsolescence losses to the minimum.

It facilitates purchasing economies through the measurement of requirements on the basis of recorded experience.

Benefits of holding Inventory

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Two questions:How Much to order?When to order ?

Inventory Models

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TOOLS AND TECHNIQUES OF INVENTORY MANAGEMENT/ CONTROL

ECONOMIC ORDER QUANTITY (EOQ) :

Economic order quantity refers to that level of inventory at which the total cost of inventory is minimum. The total inventory cost Comprising ordering and carrying costs. Shortage costs are excluded in adding total cost of inventory due to the difficulty in computation of shortage costs are excluded in adding total cost of inventory due to the difficulty in computation of shortage cost. EOQ also known as Economic Lot Size.

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Assumption of EOQ ModelDemand for the product is constant and uniform throughout the period .Lead time (time from ordering to receipt) is constant.Price per unit of product is constant.Inventory holding cost is based on average inventory.Ordering cost are constant.

EOQ FORMULA

2EOQ =

AO

c

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TOTAL COST

TOTAL ANNUAL CARRYING COSTS

TOTAL ANNUAL ORDER COSTS

EOQ QUANTITY (UNITS)

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LIMITATIONS OF EOQ Constant Usage: This may not be possible to predict , if usage varies unpredictably, as it often does , no formula will work well.

Faulty Basic Information: Ordering and Carrying costs is the baseFor EOQ calculation. It assumes that ordering cost is constant per order is fixed, but actually varies from commodity to commodity. Carrying cost also can vary with the company’s opportunity cost of capital.

Costly Calculation : In many cases, the cost estimation, cost of Possession and acquisition and calculating EOQ exceeds the savings made by buying that quantity.

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ORDER POINT PROBLEM: After determination of EOQ, then at what level should the order be placed? If the inventory level is too high , it will be unnecessary blocks the capital, and if the level is too low, it will disturb the production by frequent stock out and also involves high ordering cost. Hence, an efficient management of inventory needs to maintain optimum inventory level, where there is no stock out and the costs are minimum. The different stock levels are

a) MINIMUM LEVELMinimum stock is that level that must be maintained always, production will be disturbed, if it is less than minimum level. While determination of minimum stock level, lead time , consumption rate , the material nature must be considered

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Minimum stock level = Reorder level-[ Normal usage× Average delivery time]

b) Reordering level : Reorder level is that level of inventory at in weeks , which an order should be placed for replenishing the current stock of inventory. Generally, the reorder level lies between minimum stock level and maximum stock level.

Re-order point = Lead time (in days) × Average Daily usage

c) Safety stock: Prediction of average daily usage and lead- time is difficult. Raw materials may vary from day- to day or from week-to-week, it is in the case of lead-time also. Lead- time may be delayed , if the usage increases then the company faces problem of stock out. To avoid stock out firm may require to maintain safety stock.

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Re-order point= Lead time (in days) × Average usage + Safety stock

d) Maximum Level: Maximum level of stock , is that level of stock beyond which a firm should not maintain the stock. If the firm stocks inventory beyond the maximum stock level it is called as overstocking. Excess inventory involves heavy cost of inventory , because it blocks firms funds in investment inventory, excess , carrying cost, wastage, obsolescence, and theft cost . Hence, firm should not stock above the maximum stock level.

Maximum Stock Level= Reorder Level+ Reorder Quantity- (Minimum Usage × Minimum Delivery Time)

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e) Average Stock Level: Average Stock Level = Minimum level + [Reorder Quantity ÷ 2

(f) Danger Stock Level : Danger Level is that level of materials beyond which materials should not fall in any situation. When it falls in danger level it will disturb production. Hence, the firm should not allow the stock level to go danger level, if at all falls in that level then immediately stock should be arranged even if it costly.

Danger Level = Average Usage × Minimum Deliver Time ( for Emergency purchase)

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ABC ANALSIS It is a very effective and useful tool for classifying , monitoring and control inventories . The firm should not keep same degree of control on all the items of inventory. It is based on pareto’s of law. The firm should put maximum control on those items whose value is the highest , with the comparison of the other two items. The higher value Items are classified ‘ A items’ and would be under tight control. At the Other end of the classification, we find category ‘ C items’ , on this type of inventory we cannot afford expense of rigid controls, frequent ordering and expending because of the low value or low amounts in this area. ‘B’ items fall in between ‘A item’ and ‘ C items’ and require reasonable attention of management.

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GRAPHIC PRESENTATION OF ABC ANALYSIS

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JUST IN TIME (JIT)

In a JIT systems, material or the manufactured components and parts arrive to the manufacturing sites or stores just few hours before they are put to use. The delivery of material is synchronized with the manufacturing cycle and speed. JIT system eliminates the necessity of carrying large inventories, and thus, saves Carrying and other related costs to the manufacturer. The system requires perfect understanding and coordination between the manufacturer and suppliers, in terms of the timing of delivery and quality of material.

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TWO- BIN TECHNIQUE:It is the oldest techniques of inventory control. Generally, it is used to control ‘c’ category inventories. According to this technique, stock of each item is separated into two piles, bins or group. First bin contains stock, just enough to last from the date a new order is placed until it is received for inventory. The second bin contains stock, which is enough to meet current demand over the period of replenishment. First stock is Issued from first bin whenever the first bin is completed, then an ordered material is received.

VED CLASSIFICATION:According to this classification, inventories are grouped based on the effect of production and inventories are grouped into three are Vital, Essential and Desirable inventories. It is specially used for classification of spare parts. If a part is vital, in production, then it is classified as ‘V’, if it is essential, then it is assigned ‘ E’ and if it is

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not so essential, desirable that is given ‘D’ . ‘V’ category item are stocked high and category ‘D’ items are maintained at minimum level.

HML CLASSIFICATION:Here the materials are classified based on the unit value and not on the annual usage value. The inventory is classified into three categories such as High, Medium, and Low. As it is adopted in selective inventory control (ABC) technique. The inventory items should be listed in the descending order of unit value and it is up to the management to fix limits for three categories. This classification is useful for keeping control over consumption at department level

SDE CLASSIFICATION: This SDE classification is made based on the availability of materials. It is very much useful in the case of scarcity of supply of inventories. Here ‘S’ refers to ‘scarce’ inventory item, generally imported and those, which are in short supply category referred to as ‘D’ – ‘Difficult’ inventory

CONT…

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FSN CLASSIFICATION :Under this technique inventory is classified based on movement of inventories from stores. FSN stands for fast moving (F), slow moving(S) , and non- moving(N). This technique particularly involved in inventory useful for avoiding obsolescence. The items are usually grouped in periods of 12 months. Active moving items need to be reviewed regularly and surplus items, Non-moving items may be examined further and their disposal can be considered.

Order Cycling System : In this system periodic reviews are made of each item of inventory and orders are placed to restore stock to a prescribed supply level .

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Approaches to Inventory systems:Two general approaches to inventory system,

a) Fixed order Quantity system (‘Q’ system) Fixed quantity of materials is ordered whenever the stock level researches to the re-order level.

b) Fixed order Periodic System ( ‘P’ system) Stock position of each item of material is reviewed periodically

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Computerized inventory control system :It enables a company to easily track large items of inventories . It is an automatic system of Counting inventories , recording withdrawals and revising the balance. There is an in-built System of placing order as the computer notices that the reorder point has been reached. The computerized inventory system is inevitable for large retail stores , which carry thousand items

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THANK YOU