7.2.4 Safety stock (SS)
To safeguard against unforseen events that could cause the firm to run out of inventory and lose sales, some minimum level of inventory (inventory is also called 'stock') must be kept. Without perfect knowledge about demand patterns or re-order lead-times, it is difficult to decide on a re-order point. The answer is to hold a certain level of safety stock, which reduces the risk of running out of inventory. The larger the safety stock held the lower the risk of running out of stock.
Safety stock levels are usually established by management policy. Such a policy decision considers the degree to which back ordering is acceptable to its customers and the loss of goodwill (in sales forgone) that could arise through an out-of-stock condition. In this case safety stock levels are set by the rate of demand for a product.
Note re-order point calculations are affected by the amount of safety stock held. Under such conditions, the re-order point will be the safety stock plus the demand during lead-time.
Example
You are asked to advise management on its current inventory management policy. Management provides the following information about one of its top-selling items.
- The annual demand is 9000 units and the current policy places an order for 750 units on the first day of each month
- The cost per unit is $12.00
- Company sales records show that demand is uniform over time
- The ordering costs are $80 per order and the annual holding costs are estimated to be 25% of the average cost of inventory held (carried)
- The company has good relationships with its suppliers and can reasonably expect any of its orders to be filled within 6 working days
- The company holds a minimum safety stock level to cover demand for a 5 work ing-day period. Assume 250 working days per year.
- What is the total relevant cost of the current inventory policy? (Remember to include safety stocks)
- What is the economic order quantity?
- What will be the total relevant cost (including safety stocks) if the company uses the economic order quantity?
- What is the re-order point?
Answers
- Total relevant cost
Safety stock = (demand per day) x safety period = (9000/250)5 days = 36 x 5 = 180 units
average inventory = safety stock + (order quantity/2) = 180 + (750/2) = 180+ 375 = 555 units
annual holding costs = average inventory x H = 555 x (25% x $12) = 555 x 3 = $1665
annual order costs = orders per year x OC = 12 x $80 = $960
total relevant cost (including safety stock) = annual holding costs + annual order costs = 1665 + 960 = $2625 per annum
- Economic order quantity
EOQ = 2DC = 2 x 9000 x 80 = 480 000 = 693 units per order H 3
- Total relevant costs for EOQ (including safety stocks)
TRC = (O x EOQ) + (CHx SS) = (3 x 693) + (3 x 180) = $2619
- Re-order point (ROP)
ROP = SS + (demand during lead-time) = 180 x (36 x 6) = 396 units