3/3/2014

1
Manajemen
persediaan
Minggu ke -4
Apa itu persediaan
Finished goods
Raw materials
Work-in-process (WIP)
Good in transits
Maintenance, repair, and operational supplies
(MRO) Spareparts item that do not become part
of the product
3/3/2014
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Dimana adanya persediaan?
Material
sources
Inbound
transportation
Production Outbound
transportation
Finished goods
warehousing
Customers
Inventory
locations
Finished goods S
h
i p
p
i n
g
Inventories
in-process
R
e
c
e
i v
i n
g
Production
materials
Ballou (2004) Prentice Hall, Inc.
Keputusan Utama pada Manajemen
Persediaan
Barang mana yang perlu di-stock?
Di mana barang mau disimpan? Terpusat
atau tersebar?
Berapa banyak tiap barang harus
disimpan?
Kapan suatu barang harus dipesan?
Berapa ukuran pesanan yang harus
dilakukan?
Pujawan, Materi perkuliahan TI-ITS
3/3/2014
3
Tujuan dari persediaan
Good inventory management is a careful balancing act between stock
availability and the cost of holding inventory.
Service objectives
- Setting stocking levels so that there is only a specified probability of
running out of stock
Cost objectives
- Balancing conflicting costs to find the most economical replenishment
quantities and timing
Customer Service ,
i.e., Stock Availability
Inventory Holding costs
Ballou (2004) Prentice Hall, Inc.
Video
3/3/2014
4
Alasan perlunya persediaan
Improve customer service
- Provides immediacy in product availability
Encourage production, purchase, and
transportationeconomies
- Allows for long production runs
- Takes advantage of price-quantity discounts
- Allows for transport economies from larger
shipment sizes
Ballou 2004) Prentice Hall, Inc.
Alasan perlunya persediaan?
Act as a hedge against price changes
- Allows purchasing to take place under most favorable price
terms
Protect against uncertainties in demand and lead
times
- Provides a measure of safety to keep operations running
when demand levels and lead times cannot be known for
sure
Act as a hedge against contingencies
- Buffers against such events as strikes, fires, and disruptions
in supply
Ballou 2004) Prentice Hall, Inc.
3/3/2014
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Type dari persediaan
Pipeline
- Inventories in transit
Speculative
- Goods purchased in anticipation of price increases
Regular/Cyclical/Seasonal
- Inventories held to meet normal operating needs
Safety
- Extra stocks held in anticipation of demand and
lead time uncertainties
Obsolete/Dead Stock
- Inventories that are of little or no value due to being out
of date, spoiled, damaged, etc
Ballou 2004) Prentice Hall, Inc.
Philosofi dari persediaan
Pull
- Draws inventory into the stocking location
- Each stocking location is considered independent
- Maximizes local control of inventories
Push
- Allocates production to stocking locations based on
overall demand
- Encourages economies of scale in production
Just-in-time
- Attempts to synchronize stock flows so as to just
meet demand as it occurs
- Minimizes the need for inventory
Ballou 2004) Prentice Hall, Inc.
3/3/2014
6
Philosofi dari persediaan
Supply-Driven
- Supply quantities and timing are unknown
- All supply must be accepted and processed
- Inventories are controlled through demand
Aggregate Control
- Classification of items:
Groups items according to their sales level
based on the 80-20 principle
Allows different control policies for 3 or more
broad product groups
Ballou 2004) Prentice Hall, Inc.
Push vs Pull
Plant
Warehouse #1
Warehouse #2
Warehouse #3
A
1
A
2
A
3
A = Allocation quantity to each warehouse
Q = Requested replenishment quantity
by each warehouse
Q
1
Q
2
Q
3
Demand
forecast
Demand
forecast
Demand
forecast
PULL - Replenish inventory with
order sizes based on specific needs
of each warehouse
PUSH - Allocate supply to each
warehouse based on the forecast
for each warehouse
Ballou (2004) Prentice Hall, Inc.
3/3/2014
7
Inventory Costs
Inventory holding costs
Order costs
Shortage / stockout costs
Pujawan, Materi perkuliahan TI-ITS
Biaya Simpan (holding costs)
Biaya persediaan per tahun ada pada kisaran 25% -
35% dari nilai barang yang disimpan.
Pujawan, Materi perkuliahan TI-ITS
3/3/2014
8
Biaya Pesan / Order Costs
On average about US$ 215 per purchase order
(basen on a survey in USA). It should be lower in
Indonesia.
This includes: labor costs, equipment costs, and
materials/consumables necessary for making an
order (like paper, catridge, etc)
The magnitude is affected by the complexity of
purchase.
Pujawan, Materi perkuliahan TI-ITS
Biaya Shortage / Stockout
Count be quite small or very large, depending on
the situation
Give examples where shortage cost is very large
Give some examples how would you assess
shortage costs for a consumer product!
Pujawan, Materi perkuliahan TI-ITS
3/3/2014
9
Pola biaya persediaan
C
o
s
t
Replenishment quantity
Stockout cost
Procurement cost
Total cost
Minimum cost
reorder quantity
Ballou (2004) Prentice Hall, Inc.
Ukuran Kinerja Sistem Persediaan
Inventory turnover ratio
Inventory days of supply
Service Level
Record accuracy
Pujawan, Materi perkuliahan TI-ITS
3/3/2014
10
Inventory Turnover Ratio
Inventory Turnover Ratio: Measures how many times or
how fast inventory is turn to the customers relative to those
kept in the warehouse.
Perhitungannya bisa didekati dengan rumus berikut:
nilai penjualan dalam setahun
Turnover ratio = ---------------------------------
nilai persediaan
Semakin tinggi nilai turnover ratio semakin bagus bagi perusahaan
Pujawan, Materi perkuliahan TI-ITS
Contoh Benchmark Inventory Turnover
Ratio
INDUSTRY UPPER
QUARTILE
MEDIAN LOWER
QUARTILE
Electronics components and
accessories
9.8 5.7 3.7
Electronics computers
9.4 5.3 3.5
Household audio & video
equipment
6.2 3.4 2.3
Household electrical
appliances
8.0 5.0 3.8
Industrial chemicals
10.3 6.6 4.4
Dairy products
34.4 19.3 9.2
Publishing and printing
9.8 2.4 1.3


Pujawan, Materi perkuliahan TI-ITS
3/3/2014
11
Inventory Days of Supply
Jumlah hari yang bisa dicover oleh rata-rata inventory.
Dipengaruhi oleh lead time pengadaan, pola permintaan,
harga, dan ketidakpastian supply.
Inventory days of supply bisa dihitung per item atau
diaggregasikan untuk semua item.
Rata-rata nilai inventory
Perhitungan IDS: ============================
Rata-rata pemakaian per hari
Pujawan, Materi perkuliahan TI-ITS
Example
Product Unit price Annual Sales
Average
Inventory
A1 2 1020 100
A2 15 800 180
B1 8 65 12
B2 30 180 25
B3 6 2500 195
What is inventory turnover ratio and inventory days of supply for
each item, each group (A and B) and the whole products. Working
days in one year is 250.
Pujawan, Materi perkuliahan TI-ITS
3/3/2014
12
Akurasi Catatan Persediaan
Bisa dihitung dengan mencari persentase catatan yang
sama dengan jumlah fisiknya.
Salah satu cara untuk menaksir akurasi catatan
persediaan adalah dengan Cycle counting. Cycle
counting disebut juga sebagai stock opname atau
physical counting. Intinya adalah melakukan
pencocokan antara berapa yang ada di catatan dengan
berapa yang ada di gudang.
Misalkan dari 1000 barang yang disampel ternyata 150
diantaranya ada deviasi antara catatan dan jumlah fisik
maka akurasi catatan inventory adalah 850/1000 x
100% = 85%.
Pujawan, Materi perkuliahan TI-ITS
Customer Service Measures
Availability (stockout frequency, fill rate, perfect
order fulfillment)
Operational performance (speed, consistency,
recovery)
Pujawan, Materi perkuliahan TI-ITS
3/3/2014
13
Cost/Revenue trade-offs
Service level
cost
Inventory
Pujawan, Materi perkuliahan TI-ITS
Inventory Vs Service Level
Define service level = ( 1 probability of stockout
at the end of an order cycle)
Assume that demand follows a normal distribution
with mean M and standard deviation s
Lead time is consant = L
Develop a table showing the level of safety stock
needed to achieve different service level
What is the impact of increasing service level from
95% to 99% on safety stock level?
Pujawan, Materi perkuliahan TI-ITS
3/3/2014
14
Implications of Strategy on Inventory / Service
Level
Efficient:
Lower inventory,
turnover ratio is very
important to control
Easier to achieve high
service level due to
predictable demand
Responsive:
Higher inventory,
product availability is
critical
Difficult to eachive
high service level due
to uncertain demand
(and high service level
maybe obtained
through high costs)
Pujawan, Materi perkuliahan TI-ITS
Inventory Pooling
Pooling means that inventory serving different markets is
located centrally in a certain location.
This is normally to reduce costs for items with uncertain
demand and high carrying costs.
Example:
You manage two products to serve 5 market regions. Assume
that demand for product A in each market region is
normally distributed with mean 1000 and standard
deviation 100. For product B, demand is normally distributed
with mean 100 and standard deviation 70. Price for product
A is Rp. 10.000 per unit, but for product B is Rp. 90.000 per
unit. For both items, compare the total safety stock between
centralized and decentralized policy.
3/3/2014
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Vendor Managed Inventory (VMI)
VMI adalah model dimana pelanggan tidak lagi
memesan, namun hanya memberikan informasi posisi
inventory dan data permintaan. Vendor akan menentukan
keputusan replenishment.
VMI tidak mengatur ownership dari inventory (VMI tidak
sama dengan consignment).
Persyaratan:
Ada mekanisme sharing informasi secara cepat dan akurat
dari buyer ke vendor
Vendor memiliki kemampuan untuk mengambil keputusan
replenishment
Pujawan, Materi perkuliahan TI-ITS
Important in Managing Inventory
Information visibility
Collaboration
Consolidation
Data accuracy
Pujawan, Materi perkuliahan TI-ITS
3/3/2014
16
An Example of Consolidation
Sebuah perusahaan membeli oli dalam jumlah yang cukup besar
per bulan untuk kebutuhan mesin-mesinnya. Perusahaan memiliki 5
pabrik yang berlokasi di suatu wilayah. Pengadaan oli dilakukan
dengan cara sebagai berikut. Tiap ada kebutuhan, wakil dari
pabrik akan membuat dokumen permintaan pembelian yang
namanya purchase requisition (PR). PR akan diproses lebih lanjut
oleh buyer (di bagian pengadaan) menjadi purchase order
(dokumen pembelian yang akan dikirim ke supplier). Pengadaan
barang-barang (termasuk oli) untuk tiap pabrik dikerjakan oleh
buyer yang berbeda. Data dalam suatu bulan menunjukkan
bahwa PR oli dari tiap pabrik adalah seperti pada tabel
terlampir.
Pujawan, Materi perkuliahan TI-ITS
Hari ke Pabrik 1 Pabrik 2 Pabrik 3 Pabrik 4 Pabrik 5
1 100 150
2
3
4 250
5 110 200
6
7 110
8 120
9 220
10 180
11 100
12
13
14 100
15
16 220 150
17
18 200
19
20 140
21
Berapa biaya pemrosesan
pengadaan yang terjadi
saat ini (satu PO rata-
rata biayanya Rp. 750
ribu)
Bila dikonsolidasi tiap
minggu, berapa
penghematannya? Apa
konsekuensi negatifnya?
Pujawan, Materi perkuliahan TI-ITS