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Inventory Management
There are three common inventory mistakes people make.
1. Get it on order as soon as possible. The
thinking is the sooner product is put on order the sooner it is
shipped, the more likely the distribution center will have product
available to ship to their customers. Unfortunately, it is more
difficult to order product needed for future months than for future
weeks because it is more likely the forecast will be wrong the
farther out in the future sales are forecasted. The result is a lot
of items on order and in inventory and a lot of emergency orders to
get what is really needed.
2. Increase inventory on the hard to forecast items because
they are more likely to be out of stock. The logic is that hard
to forecast items need additional inventory to protect against
forecast error. Unfortunately, carrying extra inventory on these
items ensures there
will be a significant amount of slow moving inventory and a
greater possibility for out of stocks popular fast moving items. The
reason this is true is that forecast error can be positive or
negative. The extra inventory on all the slow moving items will
protect all of them against positive forecast error and will leave
half of them with excess inventory. To make up for this extra
inventory, lowering the inventory on popular items means when there
is an out of stock it a larger amount of sales that will be lost.
The real objective is to minimize lost sales dollars not to minimize
the number of items out of stock.
3. When there is an out-of-stock or an
overstock, check the forecast accuracy. This would make sense if
the following problems were extremely unlikely: suppliers who
shipped late or who short shipped, inventory record errors, open
order errors, inability to accurately know what is intransit,
failure to communicate discontinued items or new products, inability
to manage use up of the discontinued inventory before the new
inventory is shipped to customers.
Focus Forecasting
Here are the forecasting requirements for quick a
response competitor. They are conveniently shaped around the very
popular Focus Forecasting strengths. Most people would agree they
are an excellent place to begin.
The forecast must be:
1. As accurate as possible
2. Easy to understand
3. Require very little maintenance
4. Quickly generated
If the forecast is not accurate people will not
use it. People have got to believe they have the very best forecast
possible. One very effective way to convince people the forecast
system does provide accurate forecasts is to compare forecasts of
different systems or different strategies for past periods and
determine what is the best forecasting strategy or system. The
forecast system you choose should be the most accurate strategy or
system available. Notice there is no need to set a specific accuracy
percentage. Playing can you outguess Focus Forecasting is one way to
convince people Focus Forecasting is more accurate than a person's
judgement. Comparing how Focus Forecasting and other forecasting
systems would have forecast sales is another way to convince people
that Focus Forecasting provides a more accurate forecast.
People need to understand how the forecast was
developed in order to believe in it. Focus Forecasting quickly
compares the forecast accuracy of fifteen formulas using past sales
history for each item in order to select the best formula for each
item. Focus Forecasting uses the formula it found most accurate in
the past to forecast the future. The formulas are simple. Formulas
used by Focus include: sales will be an average of the past twelve
months, sales will be the same as last year, sales will be the same
as last year plus ten percent, etc. All of the formulas are very
easy to understand.
Focus Forecasting requires almost no maintenance.
Detail forecasts are reviewed on an exception basis and usually to
help develop estimated sales during promotion periods or to add some
other marketing intelligence amendment to the forecast. These
amendments to the forecast are called special requirement quantities
and are added to the forecast to become gross requirements for
Distribution Resource Planning. Because there is no need to review
forecasts, the person responsible for managing the forecasting
process can spend time gathering outside information such
as promotions, price changes, new markets, new
customers, new product introductions, product phase outs, the
effects of competitor actions,etc.
Competing with quick response performance means there is not a
lot of time to analyze the data. Inventory management decisions are
being made daily and whether or not the forecast has been finalized
makes no difference. Focus Forecasting will forecast thirty-two
thousand items in under 4 minutes.
To be Continued
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