Inventory Management

UNIT 15 INVENTORY MANAGEMENT

Structure Page Nos.
15.0 Introduction
15.1 Objectives
15.2 Reasons for Holding Inventory
15.3 Objectives of Inventory Management
15.4 Techniques of Inventory Control
15.4.1 Traditional Techniques
15.4.2 Modern Techniques
15.5 Summary
15.6 Key Words
15.7 Solutions/Answer to Check Your Progress
15.8 Self-Assessment Questions/Exercises

15.0 INTRODUCTION
Inventory management helps companies identify which and how much stock to order
at what time. It tracks inventory from purchase to the sale of goods. The practice
identifies and responds to trends to ensure there’s always enough stock to fulfill
customer orders and proper warning of a shortage. Inventory management is vital to a
company’s health because it helps make sure there is rarely too much or too little
stock on hand and limiting the risk of stockouts. Most firms build and maintain
inventories in the course of doing business. Manufacturing firms hold raw material,
work in process, finished goods and spares in inventories. Financial services firms
hold inventories in the form of portfolio of marketable securities consisting of debt,
equity and hybrid instruments. Retails firms (Shops, shopping malls, super markets
etc.) hold inventories to meet demand for products from customers.

In case of manufacturing firms, inventories represents largest asset category, next only
to plant and machinery. The proportion of inventory to total assets ranges between 15
to 30 percent.

Inventory management is not an isolated activity; it requires coordination among the

production, purchasing and marketing departments. Decisions regarding of the
purchase raw material are taken by the purchasing and production department,
whereas work in process inventory is influenced by the production department.
Finished goods inventory levels are decided by both the production and marketing
departments. Since these entire decision ends up in tying of resources the financial
manager has the responsibility to ensure that the inventories are properly monitored
and controlled.

15.1 OBJECTIVES
After going through this unit, you will be able to:
 highlight the need for and nature of inventory;
 explain the techniques of inventory management;
 discuss the need for analyzing inventory problems, and
 describe the process for managing inventory.

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15.2 REASONS FOR HOLDING INVENTORY
Inventory is a necessary evil that every organization would have to maintain for
various purposes. Optimum inventory management is the goal of every inventory
planner. Over inventory or under inventory both cause financial impact and health of
the business as well as effect business opportunities.
Inventories are held basically to smoothen the operations of the firm. Shortage of
inventory at any point would disrupt operations resulting in either idle time for men
and machine or lost sales. A manufacturing firm may have inventories of different
stages in the production process.
1) Inventory of raw material are held to ensure that the production process is not
disrupted due to shortage of raw material. The amount of raw material
inventory would depend upon the speed at which the raw material can be
procured; the greater the speed, lower would be the level of raw material
inventory. Higher the uncertainty in the supply of raw material, higher would be
the level of raw material inventory.

2) Work in process (WIP) inventories arises in the process of production. These

type of inventories are also referred to as “Process Inventories”. In case of
simple products the WIP inventories would be less, whereas in case of complex
products requiring various sub-processes and sub-assemblies the work in
process inventory would be high.
3) Finished goods inventories are held to meet customers requirement
promptly. The quantum of finished goods inventory would depend upon:

 time required to fill an order from the customer. If the products is of

such nature that any unexpected demand can be met at short notice the
level of inventories would be lower, and

 diversity of the product line: Firms selling a wide range of products

generally need to invest more in finished goods.

4) Inventories are also held, so that the order cost is reduced.

5) Spares: An inventory of spare items which are required for the smooth running
of business is also kept.
6) Transaction/Precautionary and Speculative Motives: Inventories which are held
for conducting normal day to day business are known as transaction inventory.
Precautionary inventories are those inventories which are held to ensure that in
case of shortage or adverse price movement, the production process will not be
stopped due to the lack of inventory.

15.3 OBJECTIVES OF INVENTORY

MANAGEMENT
The twin objectives of inventory management are operational and financial. The
operational objective means that the materials and spares would be available in
sufficient quantity on time so that work is not disrupted for want of inventory. The
financial objective means that investment in inventories should not remain idle and
minimum amount of capital should be locked in inventories. The objectives of
inventory management are summarized as follows:

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Operating Objectives Inventory Management

1) to ensure continuous supply of materials

2) to ensure uninterrupted production
3) to minimize risks and losses
4) to ensure better customer service
5) to avoiding stock out danger.

Financial Objectives
1) to minimize investment
2) to minimize inventory related costs and
3) to ensure economy in purchasing

Factors Affecting Level of Inventory

As stated in the previous sections the firm should maintain its inventory at reasonable
level. The quantum of inventory depends upon several factors, some of the important
factors are mentioned below:

 Nature of Business
 Inventory Turnover
 Nature and Type of Product
 Market Structure
 Economies of Production
 Inventory Costs
 Financial Position
 Period of Operating Cycle
 Attitude of Management

15.4 TECHNIQUES OF INVENTORY CONTROL

Inventory control signifies a planned approach of ascertaining when to buy, how much
to buy and how much to stock so that costs involving buying and storing are optimally
minimum, without interrupting production or affecting sales. There are various
techniques used to control inventory. These techniques are divided into two categories
Traditional Techniques and Modern Techniques

15.4.1 Traditional Techniques

Inventory Control Ratios
For purposes of monitoring the effectiveness of inventory management it is helpful to
look at the following ratios and indexes:

Cost of goods sold

Overall Inventory Turnover Ratio =
Average total inventories at cost

Annual consumption of raw material

Raw Material Inventory Turnover Ratio =
Average raw material inventory

Work-in-process Inventory Turnover Ratio =

Cost of manufacture
Average work in process inventory at cost

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Finished Goods Inventory Turnover ratio =
Cost of goods sold
Average inventory of finished goods at cost
Average Age of Raw Materials in Inventory =
Average Raw Material Inventory at cost
Average Daily Purchase of Raw Materials

Average Age of Finished Goods Inventory =

Average finished goods inventory at Cost
Average cost of goods manufactured per day

Number of times out of stock

Out-of-stock Iindex =
Number of times requisitioned

Value of Spare Parts Inventory

Spare Parts Index =
Value of Capital Eeuipment
Two Bin Systems
Under this system all inventory items are stored in two separate bins (two bins for
each type of inventory items). In the first bin a sufficient supply of inventory is stored
which is going to be used over a designated period of time. In the second bin a safety
stock is maintained which is going to be used during lead times. As soon as material
in the first bin is consumed an order for further stock is placed and in the meantime
inventory from the second bin is used. On receipt of new order, second bin is restored
and the balance is put in the first bin. In this system depletion of inventory in the first
bin automatically generates a signal to re-order that particular inventory.
Perpetual Inventory System
In this type of system store balances are computed and recorded after each and every
issue and receipt. The main focus of this system is to make available details about the
quantity and value of stock at all points of time. If the balance of any item of
inventory falls below a particular pre-determined level the order is placed for a further
quantity of inventory. In this system physical verification is done after every issue and
receipt as a result of which this system is costly, but at the same time materials
statement, monitoring and follow up action can be smoothly carried out.
Periodic Inventory System
Under this system all stock levels are reviewed after a fixed time interval, depending
upon the importance of the item. Imported items may require a shorter review cycle,
whereas slow moving items may require a longer review cycle. In practice the review
of stock items takes place at the end of the accounting period. At the time of review,
orders are placed for further stocking up to a pre-determined level. Under this system
the order point is not actually determined but the time of review itself is an indication
to place further orders.

 Check Your Progress 1

1. A Publishing house purchases 2,000 units of a particular item per year at a unit
cost of Rs. 20. The ordering cost per order is Rs. 50 and carrying cost is Rs. 25.
Find the optimal order quantity and minimum total cost including purchase

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 cost. If a 3% discount is offered by the supplier for purchases in lots of 1,000 or Inventory Management
more, should the publishing house accept the proposal?
2. Keshar Limited uses annually 24,000 kgs. of a chemical which costs Rs. 1.25
per kg. Placing each order costs Rs. 22.50 and the carrying cost is 15% per year
of the inventory cost. Find Economic Order Quantity, number or orders to be placed
per year and the total inventory cost (including cost of material).
(a) If procurement time is 12 days and safety stock (minimum stock) 500 kgs.
Find the maximum inventory, re-order point and average inventory.
(b) What will be your decision if the company can get a concession of 5% on
purchase price if it orders 3000 kgs. or more? (Assume 300 days in a year).

3. Calculate the minimum stock level, maximum stock level and reordering level
from the following information.
(a) Minimum consumption = 100 units per day
(b) Maximum consumption = 150 units per day
(c) Normal consumption = 120 units per day
(d) Re-order period = 10 – 15 days
(e) Re-order quantity = 1,500 units
(f) Normal Re-order period = 12 days.
4) Two components A and B are consumed as follows:
Normal usage – 100 units per week each
Minimum usage – 50 units per week each
Maximum usage – 150 units per week each
Re-order quantity – A - 400 units; B - 600 units
Re-order period – A 6 to 8 weeks; B 3 to 5 weeks.
Calculate the following for each component:
(i) Re-order Level, (ii) Minimum Level, (iii) Maximum Level, and (iv)
Average Stock Level
15.4.2 Modern Techniques
Economic Order Quantity (EOQ) Graphical Methods
The economic order quantity can also be determined with the help of a graph. Under
this method ordering cost, carrying cost and total inventory costs according to
different lot sizes are plotted on the graph. The point at which the line of inventory
carrying cost and the ordering cost intersect each other is the economic order quantity.
At this point the total inventory cost is also minimum. The function of EOQ is
illustrated below in Figure. 15.1.

2800

2400

2000
Cost (Rupees)

E.O.Q
1600 Total Inventory Cost

1200

800 Carrying Cost

400
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0
100 200 300 400 500 600 700 800

Order Size (Units)

Figure 15.1: Function of
E.O.Q

In Figure. 15.1 costs like carrying, ordering and total cost are plotted on the vertical
axis (y) and order size is shown on the horizontal axis (x). From Figure. 15.1 one can
easily see that there is an inverse relationship between inventory carrying cost and
ordering cost i.e., inventory carrying cost increases and ordering cost decreases as the
order size increases. In the first instance the total cost line decreases as the order size
increases, but it starts increasing when decrease in ordering cost is more than off set
by the increase in carrying cost.

Assumption of the EOQ Model

The basic EOQ model is based on the following assumption:
1) The forecast usage/demand for a given period, usually one year, is known
2) The usage/demand is even throughout that period
3) Inventory orders can be replenished immediately (There is no delay in placing
and receiving orders).

There are two distinguishable costs associated with inventories: costs of ordering and
costs of carrying.

Figure 15.1 shows a graph illustrating the behaviour of the carrying cost, the ordering
cost, and the sum of these two costs. The carrying cost varies directly with the order
size (since the average level of inventory is one-half of the order size), whereas the
ordering cost varies inversely with the order size.

EOQ Formula
For determining the EOQ formula we shall use the following symbols:
U = annual usage/demand
Q = quantity ordered
F = cost per order
C = per cent carrying cost
P = price per unit
TC = total costs of ordering and carrying

Given the above assumptions and symbols, the total costs of ordering and carrying
inventories are equal to
U Q
TC   F   P  C
Q 2
In the equation, the first term on the right-hand side is the ordering cost, obtained as
the product of the number of orders (U/Q) and the cost per order (F) and the second
term on the right-hand side is the carrying cost, obtained as the product of the average
value of inventory holding (QP/2) and the percentage carrying cost C.

The total cost of ordering and carrying is minimized when:

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2FU
Q
PC
which can be obtained by putting the first derivative of TC with respect to Q and
equating it with zero.

dTC UF PC
 2  0
dQ Q 2

 2UF + Q2 PC = 0
Q2 PC + 2UF
2 UF
Q2 =
PC
2UF
Q=
PC
assuming that the second derivative condition is satisfied.
The formula embodied in the equation is the EOQ formula. It is a useful tool for
inventory management. It tells us what should be the order size for the purchase of
items and what should be the size of production run for manufactured items.

The EOQ model may be illustrated with the help of the following data relating to the
Ace Company.

U= annual sales = 20,000 units

F = fixed cost per order =Rs. 2,000
P = purchase price per unit = Rs. 12
C= carrying cost= 25 per cent of inventory value.

Plugging in these values in eq. (3.2) we get.

2  2,000  20, 000

Q=  5.164
12  0.25

Quality Discount and Order Quantity

The standard EOQ analysis is based on the assumption that the price per unit remains
constant irrespective of the size of the order. When quantity discounts are available,
which is often the case, the price per unit is influenced by the order quantity. This
violates the applicability of the EOQ formula. However, the EOQ framework can still
be used as a starting point for analyzing the problem. To determine the optimal order
size when quantity discounts are available the following procedure may be used:
1) Determine the order quantity using the standard EOQ formula assuming no
quantity discount, Call it Q*.
2) If Q* enables the firm to get quantity discount then it represents the optimal
order size.
3) If Q* is less than the minimum order size required for quantity discount (call it
Q) compute the change in profit as a result of increasing the order quantity
from Q* to Q’ as follow:

 U U   Q' (P  D)C Q * PC 
  UD     F  
 Q * Q'   2 2 

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where  = change in profit.
U = annual usages/demand
D = discount per unit when quantity discount is available
Q* = economic order quantity assuming no quantity discount
Q = minimum order size required for quantity discount
F = fixed cost of placing an order
P = unit purchase price without discount
C = inventory carrying cost expressed as a percentage.

On the right-hand side of the equation, the first term represents savings in price, the
second term represents savings in ordering cost, and the third term represents the
increase in carrying cost.
4. If the change in profit is positive, Q represents the optimal order quantity. If
the change in profit is negative, Q* represents the optimal order quantity.
To illustrate the above procedure, consider the following data pertaining to Quantum
Ltd.

U = annual usage=10,000 units

F = foxed cost per order =Rs. 150
P = purchase price per unit =Rs. 20
C = carrying cost=25 percent of inventory value
Q = minimum order size required for quantity discount=1,000 units
D = discount per unit =Re.1.

The EOQ assuming no quantity discount is

2 FU 2  150  10,000
Q* =   75 units
PC 20  0.25

Since Q* is less than Q (1,000), the change in profit as a result of increasing the order
quantity from Q* to Q is

U U  Q ' P  D C Q * PC 
UD +    F  
 Q * Q'   2 2 

10,000 10,000 
= 10,000  1 +   150
 775 1,000 
1,000 20  1 0.25 775  20  0.25 
  
 2 2 
= 10,000 + 435 – (2,375  1,938)
= Rs. 9,998.

Since the change in profit is positive, Q=1,000 represents the optimal order quantity.
It should be noted that the above procedure is based on the principle of marginal
analysis. This involves comparing incremental benefits with incremental costs in
moving from one level of inventory to another. This principle may be used to
compare a proposed order quantity with the present order quantity and more generally
for comparing any set of alternatives.
Levels

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Mini-Max System Inventory Management

Under this method the maximum and minimum level for each item of inventory are
fixed. These levels serve as a basis for initiating action so that the quantity of each
item is controlled. These levels are not permanent and likely to change with the level
of activity. The maximum level indicates the maximum quantity of an item of
inventory which can be held at a point of time. The maximum level of inventory
would depend upon the following factor:

 availability of storage space

 lead time (time required in receiving the goods ordered)
 availability of working capital
 average rate of consumption of material
 cost of storage and insurance
 risk of obsolescence and deterioration
 quantity discounts

Minimum level indicates the quantitative balance of an item of inventory, which must
be maintained in hand at all times. It is a level below which the inventories should not
fall. This level of inventory is held to avoid stock out and consequent stoppage of
production. The minimum level would depend upon:

 rate of consumption of material

 the maximum and minimum time required to acquire fresh supplies
 the re-order level.

Re-order Period (ROP)

The standard EOQ model assumes that materials can be procured instantaneously and
hence implies that the firm may place an order for replenishment when the inventory
level drops to zero. In the real world, however, procurement of materials takes time
and hence the order level must be such that the inventory at the time of ordering
suffices and meet the needs of production during the procurement period which is also
known as Lead Time.

If the usage rate of materials and the lead time for procurement are known with
certainly then the ordering level would simply be:

Lead-time in days for procurement X Average daily usage

When the usage rate and lead time are likely to vary: the reorder level should be
higher than the normal consumption period requirement during the procurement
period in order to provide a measure of safety in the face of variability of usages and
lead time. Put differently, the reorder level should be equal to:
Normal consumption + Safety stock

Safety Stock
What should be the level of safety stock? In a simple situation where only the usage
rate is variable and the maximum usage rate can be specified, the safety stock required
to seek total protection against stock out is:

(Maximum usage rate  Average usage rate)  Lead time

When both the lead time and usage rate vary, which is often the case and the range of
variation is wide, complete protection against stockout may require an excessively

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large safety stock. For example, if the lead time various between 60 days and 180
days with an average value of 90 days and the usage rate varies between 75 units and
125 units per day with an average value of 100 units per day, a safety stock of 13,500
units is required for complete protection against stockout. This has been worked out
as follows:
Maximum possible usage - Normal or Average usage
Maximum daily usage - Average or Normal daily usage
X Maximum lead time  Average lead time
125  180 - 100  90 = 13,500

Since inventory-carrying costs are proportional to the level of inventories carried, it

rarely makes sense to seek total protection against stockout. In view of the trade-off
between stockout cost and inventory carrying cost, the optimal level of safety stock is
usually much less than the level of safety stock required to achieve total protection
against stockouts.
A manufacturing company will require 50,000 units of a product during the next year.
The cost of processing an order is Rs.20 and the carrying cost per units is 50 paise
per year. Lead-time of an order is 5 days and the company will keep a safety stock of
two days usage.

You are required to calculate  (i) Economic Order Quantity; (ii) Re-order Point; (iii)
Minimum Inventory; (iv) Maximum inventory and (v) average Inventory. (Assume
250 days in a year.)

Solution
(i) Economic Order Quantity
2 RO
EOQ =
C
Where; R = Annual Requirements or Usage
O = Ordering cost per order
C = Carrying cost per unit per year
2  50,000  Rs.20
EOQ =
Re .0.5
= 40,00,000 = 2,000 Units

(ii) Re-order Point

R.O.P. = (L UR) + S
Where; L = Lead Time;
U = Usage Rate (50,000  250) = 200 (units per day);
S = Safety Stock
R.O.P. = (5  200) + (2  200)
= 1,000 + 400 = 1,400 Units
(iii) Minimum Inventory
Minimum Inventory is the Safety Stock kept by the company, which are
400 units. If there is no safety stock, minimum inventory will be zero.
(iv) Maximum Inventory
Maximum Inventory = EOQ + Safety Stock
= 2,000 + 400
= 2,400 units.
(v) Average Inventory
Maximum Inventory  Minimum Inventory
2

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 2,400  400 Inventory Management
 1,400 Units
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Order Point Formula
The analysis discussed above tends to be somewhat cumbersome when probability
distributions are most complex and dependent and multi-period cases are involved. In
view of this many firms would find the following formula helpful for calculating the
reorder point.

Recorder Point = S (L) + SR (L)

Where S = Usage
L = lead time needed to obtain additional inventory when the order is placed
R =average quantity ordered
F = stockouts acceptance factor.

The value of F, the stockout acceptance factor, depends on the stockout percentage
rate.

Selective Inventory Control (Classification)

ABC Analysis:
ABC analysis [Always Better Control] is an application of the principle of
‘Management by Exception’ to the field of inventory control. If we look at the
inventory mix of a firm, it would constitute of hundreds of items. Most of these items
would be inexpensive and the frequency of their use would be less. The remaining
items would be expensive, more frequently used and account for large proportion of
firm’s investment in inventories.

It would be an expensive and cumbersome act to adopt a common policy and

determination of economic order quantity and reorder point for management of all
these items of inventory. In this technique all the items of inventory are classified in
three categories viz., A, B and C based on the usage rate, rupee value and criticality of
the item.

 A category items are those inventory items which have maximum usage rate and
constitute 70% to 80% of inventory value, but only 5% to 10% of the inventory
volume. These type of inventories requires frequent monitoring and strict control.

 B category items are those inventory items which have moderate value and usage
rate and constitute 20% to 25% of inventory value, but only 20% to 30% of the
inventory volume. These types of inventories require less monitoring and control.

 C category items are of low or negligible value and usage rate. The remaining
items of inventory representing 5% to 10% of inventory value, but 60% to 70% of
the total quantity of inventory fall in this category and require general control.

Process of ABC Analysis

 Classification: On the basis of expected use, the items of inventory are

classified according to their categories and per unit Price of each item is
determined.

 Ascertainment of Total Cost: The total cost is calculated by multiplying the

expected units to be used by the per unit cost.

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Management  Rank Determination: Cost-wise rank is determined for each item of inventory.
First rank is assigned to the item with the highest total cost.

 Computation of Ratio or Percentage: Two ratios/percentages are calculated

(i) Percentage of number of units of each item to total units of all items. (ii) Total
cost of each item to the total cost of all items.

 Determination of ABC Category: ABC categories are formed by combining the

items on the basis of their relative values.

Example 2.1: Dinesh Limited is considering selective control for its inventories.
Using the following datas, prepare the ABC plan.

Items A B C D E F G

Unit 8,000 15,000 5,000 7,5000 5,000 7,000 2,500

Unit Cost (Rs.) 5.50 1.70 30.40 1.50 0.65 5.14 51.20

Solution:
ABC Analysis
Item Per Unit Inventory Total Value
Cost (Rs.) Cate-
Units % of Cumul- Total % of Cumul- gory
Total ative % Cost Rs. Total ative %

C 30.40 5,000 10 1,52,000 38

15% 70% A
G 51.20 2,500 5 15% 1,28,000 32 70%

A 5.50 8,000 16 44,000 11

30% 45% 20% 90%
F 5.14 7,000 14 36,000 9 B

B 1.70 15,000 30 25,000 6.38

D 1.50 7,500 15 55% 100% 11,250 10% 100%

C
2.80
E 0.65 5,000 10 3,250
0.82

Total 50,000 100% 4,00,000 100%

VED Analysis:
VED (Vital, Essential, and Desirable) analysis is a technique used for spare part
inventory analysis and is widely used in the automobile industry specially for the
maintenance of the spare parts inventory. According to this technique, inventory items
are classified as follows:

 Vital (V) items constitute such items of inventory, which are vital for continuous
operations. Shortage or absence of these items will bring the production activity to
a halt. These items of inventory are critical for continuous production and
therefore require close monitoring.

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 Essential (E) items are those items of inventory, which are essential for Inventory Management
continuous production. The difference between vital and essential items is that the
shortage of essential items can be tolerated for a few hours viz., it will not bring
the production process to a halt. The level of these type of inventory is moderately
low.

 Desirable (D) items do not have any immediate impact on the production process,
hence inventory of these items may or may not be maintained.
In VED analysis the focus is not on the value of the inventory, but the focus is on their
likely impact on production.
SED Analysis
SDE (Scarce, Difficult and Easy) analysis evaluates the importance of inventory items
on the basis of their availability. As per SDE analysis the inventory items are grouped
into the following categories:

 Scarce (S) items are those items which are in short supply. Most of the time these
items are important and essential for continuous production.

 Difficult (D) items are those items which can not be produced easily.

 Easy (E) items are those items which are readily available in the market.

In SDE analysis the main focus is on the availability of the inventory. This type of
analysis is resorted to when the markets are regulated and input and output is
controlled by the government.
FSN Analysis:
Under this method inventory items are classified according to the usage/consumption
pattern. They are classified as follows:

 Fast Moving (F) items are stored in large quantities as their usage rate is high.
Special attention is given to the inventory level of these types of items.

 Slow Moving (S) items are not frequently required by the production department,
hence moderate quantities with moderate supervision are maintained.

 Non Moving (N) items are rarely required by the production department, hence
small numbers of items are kept in stores and less supervision is required for these
kind of inventory items.
In this method the focus is on the frequency of usage of a particular item.

 Check Your Progress 2

1. A Precision Engineering Factory consumes 50,000 units of a component per
year. The ordering, receiving and handling costs are Rs.3 per order while the
trucking costs are Rs.12 per order. Further details are as follows:
Interest cost Rs. 0.06 per unit per year.
Deterioration and obsolescence cost Rs. 0.004 per unit per year.
Storage cost Rs. 1,000 per year for 50,000 units.
Calculate the economic order quantity.

2. A company requires 1,250 units per month of a particular item. Ordering costs
is Rs.50 per order. The carrying cost is 15% per year, while unit cost of the
item is Rs. 10. Determine economic lot size and minimum total variable cost.

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3. The following relations to inventory cost have been established for ABC Ltd.

(a) Orders must be placed in multiples of 100 units.

(b) Requirement for the year are 3,00,000 units.
(c) The purchase price per unit is Rs. 3.
(d) Carrying cost is 25% of the purchase price of goods.
(e) Cost per order placed is Rs. 20.
(f) Desired safety stock is 10,000 units, this amount is on hand initially.
(g) Three days are required for delivery.
Calculate the following:

(i) E.O.Q.
(ii) How many orders should the company place each year.
(iii) At what inventory level should an order be placed?

4. State whether the following statements are True or False

i) Inventory management is essential because investment is stocks are high.
ii) The time required to process and execute an order is called lead time
iii) Reorder level is the quantity of materials which must be kept in stock.
iv) ABC analysis is used to manage spare parts, etc.
v) Ordering costs are the costs of purchasing materials

15.5 SUMMARY
Inventories constitute a significant portion of the current assets ranging form 40 to
60% for manufacturing companies. The manufacturing companies hold investments in
the form of raw material, work in process and finished goods. The three main motives
for holding inventories are transaction, precautionary and speculative. The various
factors which need to be considered while formulating inventory policy are:

(a) Costs
(b) Returns
(c) Risk Factors.
There are two type of costs associated with inventory maintenance which are:
(a) Ordering Costs
(b) Carrying Costs.

The Economic Order Quantity (EOQ) is that order quantity which minimises the sum
of ordering and carrying cost. The inventory level at which the firm places order for
further inventory is known as reorder point and it depends on:

(a) lead time

(b) the usage rate.
There are many inventory control systems, the most widely used one is ABC and FSN
System.

15.6 KEY WORDS

Ordering costs: Ordering costs are the costs related to the preparation of a supplier's
order, including the cost of placing an order, inspection costs

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Carrying costs: Carrying costs, also known as holding costs and inventory carrying Inventory Management
costs, are the costs a business pays for holding inventory in stock
Safety stock: Safety stock is an extra quantity of a product which is stored in the
warehouse to prevent an out-of-stock situation
Economic order quantity: The economic order quantity (EOQ) is a company's
optimal order quantity that minimizes its total costs related to ordering, receiving, and
holding inventory.
Lead Time: is the amount of time between when a purchase order is placed to
replenish products and when the order is received.
Danger level: it is the level beyond which materials should not fall in any case.

15.7 SOLUTIONS/ANSWERS TO CHECK YOUR

PROGRESS

 Check Your Progress 1

1. EOQ – 200 units; Total Cost Rs. 41,000; Net increase in total cost Rs. 325,
(Not to accept the offer.)
2. EOQ – 2,400 kg; No. of orders 10; Total Purchase cost Rs. 30,450.
(a) Maximum Inventory 2,900 kg; ROP 1,460 kg; Average Inventory
1,700 kg.
(b) Discount should be availed; saving Rs. 1,503.

3. ROL– 2,250 units; Minimum Level – 810 units; Maximum Level – 2,750
units.

4. (i) A –1,200; B –750

(ii) A – 500; B – 350
(iii) A – 1,300; B – 1200
(iv) A – 900; B – 775.

 Check Your Progress 2

1. EOQ 4.226 units

2. EOQ 1,000 units; Minimum Total Variable Cost Rs. 1,500

3. (i) 4,000 units

(ii) 75
(iii) 12,500
Assume 360 days in a year.
4. i)-T, ii)-T, iii)-F, iv)-F, v)-T

15.8 SELF-ASSESSMENT QUESTIONS/EXERCISES

1. What is meant by inventory management? Discuss the objectives of inventory
management.
2. Explain various techniques that are used for inventory management.
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Working Capital
Management
3. Define the term inventory control. What are the inventory control systems?
Explain
4. What costs are incurred in the context of inventory managements? Explain
5. Discuss the assumptions of EOQ model?
6. What is A-B-C analysis? How is it useful as a tool for inventory management?
7. How would you go about determining the optimal order size when quantity
discount is available? Illustrate your approach with a suitable example.

Exercises:

8. A manufacturing company uses Rs. 1, 00,000 materials per year. The

administration cost per purchase is Rs. 100, and carrying cost is 20% of the
average inventory. Calculate Economic Order Quantity for the company
(Ans. Rs. 10,000)
9. A manufacturer buys certain equipment from outside suppliers at Rs. 30 per
unit. Total annual needs are 800 units. The following further data are available:
Annual return on investment, 10%. Rent, insurance, taxes per unit per year, Re.
1, Cost of placing an order, Rs. 100. Determine the Economic Order Quantity.
(Ans. 200 units)

10. Find out the Economic Order Quantity and Order Schedule for raw materials
and packing materials with the following data given to you:
(a) Cost of Ordering: Raw materials : Rs. 1,000 per order
Packaging materials: Rs. 5,000 per order

(b) Cost of holding inventory: Raw materials: 1 P. per unit p.m.

Packaging materials: 5 P. per unit p.m.

(c) Production rate: 2, 00,000 units per month.

(Ans. 2, 00,000 units: 2, 00,000 units)
11. What do you understand by Maximum level, Minimum level, Re-ordering
level? Calculate the above from the following data:
Re-order quantity 1,500 units
Re-order period 4 to 6 weeks
Maximum consumption 400 units per week
Normal consumption 300 units per week
Minimum consumption 250 units per week
Ans. Re. order quantity 2,400 units: Maximum level 2,900 units:
Minimum level 900 units
12. Two materials, X and Y are used as follows:
Minimum usage-50 units per week each;
Maximum usage-150 units per week each;
Normal usage-100 units per week each:
Ordering quantity: X-500 units and Y-1,000 units:

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 Delivery period: X-4 to 6 weeks: Y-2 to 4 weeks. Inventory Management

Calculate for each material:

(a) Minimum Level. (b) Maximum Level, (c) Ordering Level.

(Ans.(a) X = 400 units. Y = 300 units: (b) X = 1,300 units, Y = 1,500 units:
(c) X = 900 units, Y = 600 units)

13. The following information is available in respect of component 020:

Maximum stock level: 8,400 units
Budgeted consumption: Maximum 1500 units per month
Minimum 800 units per month
Estimated delivery period: Maximum 4 months
Minimum 2 months
You are required to calculate
(a) Re-order level
(b) Re-order quantity.
(Ans. (i) 6,000 units: (ii) 4,000 units)
14. Smart Ltd. buys in lot of 125 boxes which is a three month supply. The cost
per box is Rs. 125 and the ordering cost is Rs. 250 per order. The inventory
carrying cost is estimated at 20% of unit value per annum. You are required to
ascertain
(i) What is the total annual cost of the existing inventory policy?
(ii) How much money would be saved by employing the economic order
quantity (EOQ)?
(Ans. (1) Rs. 65,063; (ii) Rs. 63)

15 Ace Ltd. manufactures a product and the following particulars are collected
for the year ended March, 2021:
Monthly demand 1000 Units
Cost of placing an order Rs. 100
Annual carrying cost Rs. 15 per unit
Normal usage 50 units per weak
Minimum usage 25 units per week
Maximum usage 75 units per week
Re-order period 4-6 weeks
You are required to calculate:
(i) Re-order quantity
(ii) Re-order level
(iii) Minimum level
(iv) Maximum level
(v) Average stock level

Ans. (i) 186 units, (ii) 450 units: (iii) 200 units: (iv) 536 units: (v) 368
units, or 293 units)

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