Intended learning outcomes: Produce an overview on joint replenishment: kit materials management and collective materials management.
Continuation from previous subsection (11.4.4)
3. Joint replenishment is joint planning for a group of related items, treating them as an item family.
Two examples of management of sets of items follow.
3a. In kit materials management, various goods are combined into a so-called (material) kit (because of their joint use in particular assemblies or products) and managed as a group.
The individual optimum batch size for an element i from a kit S with annual consumption AC of S results from the formula in Figure 11.4.4.4.
Fig. 11.4.4.4 Individual optimum batch sizes for an element i of kit S with annual consumption ACS.
Instead of these individual batch sizes, we may determine a kit batch size XS using the compromise formula in Figure 11.4.4.5.
Fig. 11.4.4.5 Kit batch size XS.
If the component kits are very heterogeneous with respect to the two factors in the batch size formulas above, we can form more homogeneous planning subgroups that are then used for separate batch sizings. Another possibility is to form an economic batch for the most value-intensive components. We then set the batch size of less value-intensive materials positions as whole-number multiples of this batch for correspondingly less frequent procurement.
3b. In collective materials management, we form material groups, or planning groups, whose setup and ordering costs can be reduced, if the batches are ordered collectively.
Valid criteria for collective materials management include:
- The same supplier for purchased parts (taking advantage of simplified administration and/or a total invoice discount)
- The same production technique for in-house production (e.g., for a product family), whereby simplified machine setup achieves a reduction in the total setup costs
In the case of collective materials management, within a planning group materials managers must determine an average reduction in the setup and ordering costs as a percentage. As soon as an item is to be ordered, a check is made of all other items of the same planning group. If the order of a batch is due in the near future anyway, it can be ordered now through an early order release. This should be a reduced batch size, which is calculated by using the reduced setup and ordering costs.
Course section 11.4: Subsections and their intended learning outcomes
11.4 Batch Sizing, or Lot Sizing
Intended learning outcomes: Produce an overview on production or procurement costs, batch-size-dependent unit costs, setup and ordering costs, and carrying cost. Explain optimum batch size, optimum length of order cycle, the classic economic order quantity formally and in practical application. Disclose extensions of the batch size formula.
11.4.1 Production or Procurement Costs: Batch-Size-Dependent Unit Costs, and Setup and Ordering Costs
Intended learning outcomes: Differentiate between batch-size-dependent production or procurement costs and batch-size-independent production or procurement costs.
11.4.1b Carrying Cost
Intended learning outcomes: Explain carrying cost and carrying cost rate. Produce an overview on costs of financing or capital costs, storage infrastructure costs and the risk of depreciation.
11.4.2 Optimum Batch Size: The Classic Economic Order Quantity (EOQ)
Intended learning outcomes: Explain the concept of the economic order quantity (EOQ). Explain variables for the EOQ formula.
11.4.2b The Economic Order Quantity (EOQ) Formula
Intended learning outcomes: Explain the economic order quantity (EOQ) formula. Describe the cost curves as a function of batch size.
11.4.2c Optimum Length of Order Cycle
Intended learning outcomes: Present the optimum length of order cycle.
11.4.3 Economic Order Quantity (EOQ) Formula: Sensitivity Analysis
Intended learning outcomes: Present in detail the sensitivity analysis of the EOQ calculation.
11.4.3b Economic Order Quantity (EOQ) and Optimum Length of Order Cycle in Practical Application
Intended learning outcomes: Produce an overview on the practical implementation of the EOQ formula. Identify several factors that influence a maximum or minimum order quantity.
11.4.4 Extensions of the EOQ Formula: Lead-Time Orientation and Discount Levels
Intended learning outcomes: Present lead-time-oriented batch sizing. Describe batch sizing considering discount levels.
11.4.4b Extensions of the EOQ Formula: Joint Replenishment
Intended learning outcomes: Produce an overview on joint replenishment: kit materials management and collective materials management.
