06_CPIM BSCM_PPT_v3_0_VCppt课件.ppt

6 1 2009APICSCONFIDENTIALANDPROPRIETARY AggregateInventoryManagement APICSCertifiedinProductionandInventoryManagement CPIM Session6 BasicsofSupplyChainManagement Ch9 2009APICSCONFIDENTIALANDPROPRIETARY 6 2 BasicsofSupplyChainManagement IntroductiontoSupplyChainManagement AggregateInventoryManagement DemandManagement ItemInventoryManagement CapacityManagementandProductionActivityControl TheoryofConstraintsandReviewActivity MaterialRequirementsPlanning Lean JITandQualitySystems MasterPlanning PurchasingandPhysicalDistribution 1 2 3 4 5 6 7 8 9 10 2009APICSCONFIDENTIALANDPROPRIETARY 6 3 LearningObjectives RecognizeatleastfivedifferentclassesofinventoryExplainsixfunctionsofinventoryIdentifythreeobjectivesofaggregateinventorymanagementDeterminethefivetypesofinventorycostsExplaintherelationshipbetweenassets liabilities andowners equityonthebalancesheetExplainfinancialstatementsandtheirrelationshiptoaggregateinventoryCalculateinventoryturnsanddaysofsupplymeasurements Uponcompletionofthissession participantswillbeableto 6 4 2009APICSCONFIDENTIALANDPROPRIETARY IntroductiontoInventory Session6 AggregateInventoryManagement 2009APICSCONFIDENTIALANDPROPRIETARY 6 5 WhatisInventory Thosestocksoritemsusedtosupportproduction supportingactivities andcustomerservice APICSDictionary 2009APICSCONFIDENTIALANDPROPRIETARY 6 6 AggregateInventoryManagement ObjectivesSupportbusinessstrategyandoperationsEnsurethatinventorypracticessupportfinancialobjectivesBalancecustomerservice operationsefficiency andinventoryinvestmentcostobjectives 255 2009APICSCONFIDENTIALANDPROPRIETARY 6 7 ItemInventoryManagement ImportanceofinventoryitemsHowtocontrolinventoryitemsHowmuchtoorderatonetimeWhentoplaceanorder Managementmustestablishdecisionrulesaboutindividualinventoryitems 6 8 2009APICSCONFIDENTIALANDPROPRIETARY 8 AggregateInventoryManagement Session6 AggregateInventoryManagement 2009APICSCONFIDENTIALANDPROPRIETARY 6 9 InventoryandtheFlowofMaterials Source Arnoldetal IntroductiontoMaterialsManagement 6thed ReprintedbyPermissionofPearsonEducation 256 2009APICSCONFIDENTIALANDPROPRIETARY 6 10 ReasonsforCarryingInventory Theonlygoodreasonforcarryinginventorybeyondcurrentneedsisifitcostslesstocarryitthannot Inventoryallowsthecompanytooperatewithdifferentproductionratesandbatchsizesthroughoutthesupply production anddistributionsystem Inventorydecouples DemandfromSupplyCustomerdemandfromFinishedgoodsFinishedgoodsfromComponentavailabilityOutputofoneoperationfromOutputofprecedingoperationMaterialstobeginproductionfromSuppliersofmaterials 2009APICSCONFIDENTIALANDPROPRIETARY 6 11 FunctionsofInventory Anticipationinventory builtupinadvanceoffuturedemandSafetystock alsocalledfluctuationinventoryLot sizeinventoryTransportationinventoryHedgeinventory guardagainstfuturepriceincreaseinpurchaseditems 257 2009APICSCONFIDENTIALANDPROPRIETARY 6 12 InventoryObjectives Bestcustomerservice98 goalatLillyLow costplantoperationcampaignsinLillyMinimuminventoryinvestmentkeepaslowaspossiblewhilemaintaining1sttwo 259 2009APICSCONFIDENTIALANDPROPRIETARY 6 13 InventoryandOtherObjectives BalancecostofcarryinginventorywithcostsofnotcarryinginventoryCustomerserviceChangingproductionlevelsPlacingordersSumofthecostofcarryinginventoryandthecostofnotcarryinginventoryshouldbeaslowaspossible 6 14 2009APICSCONFIDENTIALANDPROPRIETARY InventoryCost Session6 AggregateInventoryManagement 2009APICSCONFIDENTIALANDPROPRIETARY 6 15 InventoryCosts Source Arnoldetal IntroductiontoMaterialsManagement 6thed ReprintedbyPermissionofPearsonEducation 261 2009APICSCONFIDENTIALANDPROPRIETARY 6 16 ItemCosts 2009APICSCONFIDENTIALANDPROPRIETARY 6 17 Obsolescence Damage Pilferage Insurance Deterioration CarryingCosts储囤成本 OpportunityCost Space Personnel Equipment 262 2009APICSCONFIDENTIALANDPROPRIETARY 6 18 Problem6 1 Giventhefollowingpercentagecostsofcarryinginventory calculatetheannualcostiftheaverageinventoryis 1 000 000 Capitalcosts 6 Storagecosts 9 Riskcosts 10 2009APICSCONFIDENTIALANDPROPRIETARY 6 19 Problem6 1Solution Totalcostofcarryinginventory 6 9 10 25 Annualcarryingcost 25 1 000 000 250 000 2009APICSCONFIDENTIALANDPROPRIETARY 6 20 OrderingCosts Purchase Factory Source Arnoldetal IntroductiontoMaterialsManagement 6thed ReprintedbyPermissionofPearsonEducation PurchasingCost ProductionControlCost SetupandTear downCost LostCapacityCost What sthiscostinLilly 263 Atthebottleneck 2009APICSCONFIDENTIALANDPROPRIETARY 6 21 Problem6 2 Giventhefollowingdata calculatetheaveragecostofplacingoneorder Annualproductioncontrolcost 200 000Averagecostofsetupandteardown 200Numberofordersperyear 20 000 2009APICSCONFIDENTIALANDPROPRIETARY 6 22 Problem6 2Solution Averagecostofplacingoneorder 200 210 200 000 20 000 FixedVariable 2009APICSCONFIDENTIALANDPROPRIETARY 6 23 StockoutCosts CAUSESOFSTOCKOUTS STOCKOUTCOSTS Demandduringleadtimeexceedsforecastandavailableinventory Productionandsupplierproblemscauseinventoryshortages Backordercosts Lostsales Lostcustomers Expediting Additionalmanufacturingandpurchasing 264 2009APICSCONFIDENTIALANDPROPRIETARY 6 24 Capacity RelatedCosts Howcanthesebeavoided Levelloading buildinginv 2009APICSCONFIDENTIALANDPROPRIETARY 6 25 Problem6 3 Totalcostofcarrying Slide6 11 inventory Beginninginv 0CalculateQlevelproductionplanDetermineendinginvCalculateAvinvInvcost avinvx 3 unit 2009APICSCONFIDENTIALANDPROPRIETARY 6 26 Problem6 3Solution Totalcostofcarryinganticipationinventory 6 000 3 000 3 000 3 000 3 000 1 000 1 000 0 0 500 1 000 500 1 500 3 000 1 500 0 0 Beginninginv 0CalculateQlevelproductionplanDetermineendinginvCalculateAvinvInvcost avinvx 3 unit 6 27 2009APICSCONFIDENTIALANDPROPRIETARY FinancialStatementsandInventory Session6 AggregateInventoryManagement 2009APICSCONFIDENTIALANDPROPRIETARY 6 28 AccountingSystems Accountingsystemsclassifyactivitiesofacompanyintofivetypesofaccounts Balancesheetaccounts Incomestatementaccounts 1 Assets2 Liabilities3 Owners Equity 4 Revenues5 Expenses 265 Machines Accountpayable Owncapital 2009APICSCONFIDENTIALANDPROPRIETARY 6 29 BalanceSheetEquation Owners Equity Assets LiabilitiesAssetsItemsyouownLiabilitiesAmountsyouoweOwners equityWhatisleftoverafterliabilitiesarepaid Assets Liabilities Owners Equity Needtopay 2009APICSCONFIDENTIALANDPROPRIETARY 6 30 Problem6 4 a Iftheowners equityis 1 000andliabilitiesare 800 whataretheassetsworth Assets Liabilities Owners equityb Iftheassetsare 1 000andliabilitiesare 600 whatistheowners equity Owners equity Assets liabilities 2009APICSCONFIDENTIALANDPROPRIETARY 6 31 Problem6 4Solution Iftheowners equityis 1 000andliabilitiesare 800 theassetsareworth 1 000 800 1 800Iftheassetsare 1 000andliabilitiesare 600 theowners equityis 1 000 600 400 2009APICSCONFIDENTIALANDPROPRIETARY 6 32 IncomeStatement Income Revenue Expenses RevenueIncomefromsalesofgoodsandservicesIncreasesowners equity ExpensesCostsincurredinearningrevenueDecreasesowners equity 266 2009APICSCONFIDENTIALANDPROPRIETARY 6 33 IncomeStatement Revenue 1 000 000CostofgoodssoldDirectlabor 200 000Directmaterial 400 000Overhead 200 000Totalcostofgoodssold 800 000Grossmargin grossprofit 200 000Generalandadministrativeexpense 100 000Netincome profit 100 000 Taxes 2009APICSCONFIDENTIALANDPROPRIETARY 6 34 InventoryandFinancialResults Soinventoryonthebooksisnotasgoodasinventoryconvertedintoproductsandthensold Becauserawmaterialinventoryisanexpenseontheincomestatement itoffsetsrevenue whichreducesassets AndWIPandfinishedgoodsinventoryincludeallocationsofdirectlaborandfactoryoverhead i e costsaddedinproduction whichalsooffsetrevenueandreduceassets Inventoryisanassetonthebalancesheet sowhynothavemoreofit Thesaleofamanufacturedproductconvertsinventoryanditsbuiltupcostsintorevenue whichincludesaprofitmargin i e thevalueaddedbytheproductionprocess Revenuesarethushigherthancosts tothebenefitofcashandowners equityonthebalancesheet Fromasupplychainmanagementperspectiveaswell convertinginventoryquicklyintosalesisamajorobjectiveandhaspositivefinancialstatementimplications Howaggregateinventorymanagementisconcernedwiththeflowofmaterialsthroughvariousinventoryclassificationstoproduceaprofit ReducingmfgingLT increasingcashflow receivingsalescashbeforecreatinginv 2009APICSCONFIDENTIALANDPROPRIETARY 6 35 Problem6 5 Revenue CostofgoodssoldDirectlabor Directmaterial Overhead Totalcostofgoodssold Grossmargin grossprofit Generalandadministrativeexpenses Netincome profit Doprobleminyourbooknow 2009APICSCONFIDENTIALANDPROPRIETARY 6 36 Revenue CostofgoodssoldDirectlabor Directmaterial Overhead Totalcostofgoodssold Grossmargin grossprofit Generalandadministrativeexpenses Netincome profit Problem6 5Solution 1 500 000 300 000 500 000 400 000 1 200 000 300 000 150 000 150 000 Whatwouldhappentoprofitifthroughbettermaterialsmgmt materialcostswerereducedby 50 000 2009APICSCONFIDENTIALANDPROPRIETARY 6 37 CashFlowAnalysis TheinflowandoutflowofcashinthebusinessoveragivenperiodoftimeTosurvive abusinessmusthavethecashavailabletopayitsbills 267 2009APICSCONFIDENTIALANDPROPRIETARY 6 38 CashFlow 2009APICSCONFIDENTIALANDPROPRIETARY 6 39 InventoryTurns Ameasureofhoweffectivelyinventoryisbeingused Example Annualcostofgoodssold 1 000 000Averageinventory 500 000 Annualcostofgoodssold Averageinventoryindollars Inventoryturns 1 000 000 500 000 Inventoryturns 2 268 Inventoryturnover 2009APICSCONFIDENTIALANDPROPRIETARY 6 40 DaysofSupply Usedtomeasuretherelationshipbetweenusage sales andinventoryInthisexample 6 000unitsaresoldonaverageoveraperiodof30daysat200unitsperdayInventoryturnsevery30days or12timesayear inventoryturnsare12 Daysofsupply 200 6 000 30days Inventoryonhand Averagedailyusage 269 units Units day 2009APICSCONFIDENTIALANDPROPRIETARY 6 41 Problem6 6 d AnnualSavings a Inventoryturns b AverageInventory AnnualCostofGoodsSold InventoryTurns c Reductionininventory COGS 10million Avinv 2 5million COGS AVInv 4 Ifinvturns 10 Ifcarryingcost 20 Old newavinv 2009APICSCONFIDENTIALANDPROPRIETARY 6 42 Problem6 6Solution d AnnualSavings a Inventoryturns b AverageInventory AnnualCostofGoodsSold InventoryTurns c Reductionininventory 2 500 000 1 000 000 1 500 000 20 x 1 500 000 300 000 COGS 10million Avinv 2 5million COGS AVInv 4 Ifinvturns 10 Ifcarryingcost 20 Old newavinv 6 43 2009APICSCONFIDENTIALANDPROPRIETARY Wrap UpandHomework Session6 AggregateInventoryManagement 2009APICSCONFIDENTIALANDPROPRIETARY 6 44 LearningObjectives RecognizeatleastfivedifferentclassesofinventoryExplainsixfunctionsofinventoryIdentifythreeobjectivesofaggregateinventorymanagementDeterminethefivetypesofinventorycostsExplaintherelationshipbetweenassets liabilities andowners equityonthebalancesheetExplainfinancialstatementsandtheirrelationshiptoaggregateinventoryCalculateinventoryturnsanddaysofsupplymeasurements Uponcompletionofthissession participantswillbeableto 2009APICSCONFIDENTIALANDPROPRIETARY 6 45 VocabularyCheck Objective Reinforceterminologyusedinthissession Completetheactivityinclass individuallyorinpairs orashomework 2009APICSCONFIDENTIALANDPROPRIETARY 6 46 VocabularyCheckSolution 1 d2 f3 a4 j5 h6 i 7 c8 l9 e10 k11 b12 g 2009APICSCONFIDENTIALANDPROPRIETARY 6 47 Problem6 7 Giventhefollowinginformation calculatetheannualcostofcarryinginventory Ordersplacedperyear 1 000Receivingcostsperorder 15Annualofficeexpense 8 000Averageinventory 500 000Costofcapital 10 ofaverageinventoryvalueCostofstorage 8 ofaverageinventoryvalueAnnualcostofcarryinginventoryAverageinventory costofcapital costofstorage 2009APICSCONFID