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Quick Response Logistics

PART III. 

 

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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