How Many Parts to Make at Once: The Cost per Unit (CX + S)/240M + S/X + C Is Minimized Exactly at the Lot Size X = √(240MS/C)Research Paper
Motivation
Every manufacturer who makes a part in batches faces the trade-off Ford W. Harris described in 1913: large lots spread the fixed set-up cost of an order over many pieces, but they also tie up money in stock that must be carried. Harris's article "How many parts to make at once" (Factory, The Magazine of Management 10(2), 1913, reprinted in Operations Research 38(6), 1990) resolved the trade-off with a closed formula, the square-root or economic order quantity (EOQ) formula. It is the starting point of deterministic inventory theory and is still taught as the first model of every operations-management course.
Timeline. Harris published the formula in 1913, without proof ("the solution of this problem involves higher mathematics"). The same formula was popularised by R. H. Wilson in 1934 and was for decades attributed to him. D. Erlenkotter traced it back to Harris (Operations Research 38(6), 1990, 937–946), and the article was reprinted in the same issue. Later work built stochastic (Q, r) models on top of it; Zheng (1992) compared the EOQ heuristic with the optimal (Q, r) policy.
Setting
A part is used at a regular rate of units per month (the movement). Each unit costs dollars (the unit cost), and each order costs dollars to set up. Parts are made in lots of units, the lot size. Under regular movement a lot of is delivered when the stock reaches nothing and is then used up at rate , so the stock at time (months, from a delivery) is the sawtooth
with the fractional part. Interest and depreciation on stock are charged at ten per cent a year, a rate the paper fixes.
Harris prices a unit in three parts:
- the interest charge per piece: the average stock is , its value including set-up is , ten per cent of this is the annual charge, and dividing by the units used a year gives ;
- the set-up cost per piece ;
- the unit cost .
The cost per unit is therefore
and the economic lot size is . In Lean these are stockLevel, interestPerPiece, costPerUnit and econLotSize in the namespace HarrisEOQ.Lot.
Formalization targets
Goal: the square-root formula
For ,
This is Harris's claim that the value of giving the minimum value to "reduces to the square root of (240MS divided by C)": is admissible, attains the minimum, and is the only lot size that does.
Milestones: the derivation of
- The long-run average of the sawtooth stock is : .
- The interest charge per piece, built in the paper's steps, equals , and is the sum of the three per-piece costs.
These justify the objective , not its minimization; the paper gives no argument for the minimization.
Companion statements
- with (p. 948).
- The fourfold law: (p. 950).
- A lot too small by costs more than one too large by : for (p. 949, general form of an observation made on an example).
- At the optimum, (p. 948).
- The paper's three worked lot sizes 2,190, 6,850 and 48.5, each to its last printed digit (pp. 948–949).
Significance
The result. The square-root formula gives the cost-minimising batch size in closed form from three observable numbers. Its consequences are the ones Harris draws: lot sizes grow only with the square root of demand (so consumption must quadruple to double a lot), the cost curve is flat near the optimum and asymmetric (erring small is worse than erring large), and at the optimum the set-up cost balances the variable carrying cost. Every later deterministic and stochastic lot-sizing model reduces to this one in its simplest case.
Formalizing it. The result is classical and proved in textbooks, but Harris's paper itself contains no proof. A formalization supplies the missing argument for the paper's exact objective, which differs from the textbook EOQ by charging interest on the set-up cost ( in the stock value) and by the fixed ten per cent rate. It also makes the paper's modelling step precise: the claim that the average stock is becomes a statement about a time average of a sawtooth function. To our knowledge none of these statements has a machine-checked proof on the platform; the EOQ items of Zheng (1992) concern a different model, with backorders.
Difficulty
The minimization is elementary calculus; the substance of the mission is fidelity. The objective must be the display as printed, with meaning , and the claim includes uniqueness, not only that is a minimizer. The average-stock milestone needs a genuine long-run average of a discontinuous periodic function over with not a whole number of cycles, which is where the integration and limit bookkeeping lies.
Formalization scope
All quantities are real numbers; lot sizes are not restricted to integers (the paper's own optimum is 48.5). The hypotheses are not written on the page; they are implicit in the meaning of a usage rate, a price and a cost, and are added. Every quantifier over lot sizes is over . Time is measured in months, and the interest rate is fixed at ten per cent, so the constant appears as printed; the formula is not generalized to an arbitrary rate.
A trivializing formalization is ruled out: is defined as the printed display, not rewritten around ; the average stock is an integral of the stock level, never defined as ; and the goal does not quantify over all real , where Lean's convention would make a spurious minimizer.
The manufacturing interval and the safe stock minimum play no role in the formula and are not modelled. The examples' cost figures (0.188 cents, $0.00028, and so on) are not formalized. The development needs only Mathlib's real numbers, square roots, fractional parts, interval integrals and limits; contributions of proofs of any item are welcome.
Selected references
- F. W. Harris, How many parts to make at once, Factory, The Magazine of Management 10(2):135–136, 152, 1913; reprinted in Operations Research 38(6):947–950, 1990. https://doi.org/10.1287/opre.38.6.947
- D. Erlenkotter, Ford Whitman Harris and the economic order quantity model, Operations Research 38(6):937–946, 1990. https://doi.org/10.1287/opre.38.6.937
- R. H. Wilson, A scientific routine for stock control, Harvard Business Review 13:116–128, 1934.
- Y.-S. Zheng, On properties of stochastic inventory systems, Management Science 38(1):87–103, 1992. https://doi.org/10.1287/mnsc.38.1.87