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OMSAN LOJİSTİK
Information Systems to Inventory Management
Inventory Planning and Management
Latin America Logistics Center
Logistics Management Series -
Agenda
• Planning vs. Control
• Forecasting
• Fill Rate Planning
• Replenishment Planning
• Optimisation
• Supply Chain Management
Planning vs. Control
Planning
Man
ag
em
en
t
ExecutionMon
itori
ng
Inventory Control
• Fundamentals for Inventory Planning
• How Many do I have in Stock?– By Item– By Position
• Accuracy is Critical– Key Performance Indicators – % Accuracy by % de Positions
Demand Forecast
• Critical for Inventory Planning
• Question: How Many will we sale?– By Item– By Period
• Planning Horizon Coverage
• Optimal Review Intervals
• Key Performance Indicators in Demand Forecast
Forecast
A Forecast, a range & a probability
0
50
100
150
200
250
300
1 2 3 4 5 6 7 8 9 10period
Un
its
Actual
Forecast
Fill Rate Planning
• How Many in Stock to achieve the target by fill rate & ROI
• By Item, by Position, by Period
• Stock Cycles
• Safety Stock
• Stocks Building
Inventory Management in Time
0
100
200
300
400
500
600
700
1 2 3 4 5 6 7 8period
Un
its Cycle
Build
SS
Forecast
Stock of the Replenishment Cycle
• Is the Stock that results from the difference between the replenishment quantities and the quantities of the demand orders
0
50
100
150
200
250
1 2 3 4 5 6 7 8
Cycle
SS
Safety Stock
• Planned Inventory to fulfil demand overloads during lead time
02040
6080
100120
140160
1 2 3 4 5 6 7 8
SS
Actual
Plan
Building Inventory
• Planned Inventory to accumulate stock before the demand season
• Generally for periods of time in which demand exceeds production capacity
0
100
200
300
400
500
600
1 2 3 4 5 6 7 8
Inventory
Forecast
Replenishment Planning
• When does Inventory should be replenished?
• How many units?
• From which location?
• Planning Scope– Reorder Points– Distribution Requirements Planning (DRP)– Constrained Optimisation
Replenishment Planning
CustomerDC
DC
CustomerDC
Plant Plant
DC
CustomerDC
Constrained Optimisation
• Develop a plan that recognises the business constraints
• Capacity and Sequence of the Production Lines• Vehicle Capacity and Transportation Costs• Warehousing Capacity• Inventory Carrying Cost• Customer Prioritisation
• Business Performance Optimisation– Cost Minimisation & Revenues Maximisation
Constrained Optimisation
• Simultaneously consider all SKUs that share Constraints– Within the Business– Between Business
• Requires Advanced Mathematical Techniques of Optimisation– Linear Programming– Artificial Intelligence Techniques
Supply Management
• Inventory Management and Replenishment through Supply Chain Business
• More Acronyms...– QR - Quick Response – ECR - Efficient Consumer Response– VMI - Vendor Managed Inventory– CPFR - Collaborative Planning, Forecasting &
Replenishment
QR, ECR, VMI
• The Supplier is Responsible for Inventory Planning and Replenishment in the POS
• Usually occurs between big suppliers and customers
• Requires EDI or Electronic Data
• Batch Oriented , is not interactive
Local User
Internet/ExtranetCustomer,Supplier,Remote User
Forecast &Replenishment
Planning
Reviews and Confirmation
Internet Collaborative Planning
Case Study - Heineken USA
• HUSA is the only importer of Heineken to USA
• HUSA sales 150 SKUs to 450 distributors
• No Production Facilities in USA – only Marketing, Sales and Distribution
Product and Information Flow
HUSA
BreweryDistributors
Orders
Orders
Product
Objectives
• Reduce order lead time
• Provide to the Brewery better product forecast
• Improve Service Levels to and from distributors
• Improve flow of information of marketing with distributors
HOPS Characteristics
• Gathers Sales and Stocks Data
• Delivers to the Distributor a Forecast for Review and Approval
• Delivers to the Distributor an Inventory plan. Allows reviews of parameters and rules
• Delivers to the Distributor a suggested order
– Based on forecast, targets & constraints
• Real Time System
Information Flow
HUSA
BreweryDistributors
Confirmed Orders,Sales & Forecasts, Inventory Position
Distributors Orders & Aggregate Forecast
Suggested Orders,Inventory, Forecasts
Heineken Operational Planning System
Outcomes
• Better achievement of sales targets
• Dramatically improved forecasts sent to the Brewery
• Sales person dismissal from taking orders
• Four weeks reduction in customer order cycles
• Sales Increase!!!
Software for Inventory Management
• Manugistics
• Numetrix
• i2
• FYI Planner
• Lucas-Baer
• LPA
• Logility
• Information Concepts Inc.
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