8 Signs You Need Inventory Planning and Replenishment Automation

4 minread

Tags: Blog, Demand forecasting, Purchasing & replenishment

Mark Chapman

Mark Chapman   25 September 2019


Man at desk inventory planning

Index

  1. Do you need inventory planning and replenishment automation?
  2. 1: Your demand forecasting is too simplistic
  3. 2: You’re unable to forecast seasonality or deal with volatile demand fluctuations
  4. 3: Your stock levels are growing, inventory turnover is slipping
  5. 4: Your customer service levels are highly variable
  6. 5 There's a growing trend of lost sales or accounts
  7. 6 You are constantly fire-fighting
  8. 7 Inventory replenishment is time-consuming
  9. 8 You're unable to manage varying supplier lead times
  10. Know your inventory planning and replenishment limits!

Do you need inventory planning and replenishment automation?

Enterprise Resource Planning (ERP) platforms are a big investment for any organisation. They also take a lot of time and resources to design, specify and implement. But once they’re up and running, there’s no doubt they offer a wealth of benefits, including streamlined processes, improved productivity, centralised data and better departmental collaboration.

However, unfortunately for inventory management teams, ERPs often lack functionality when it comes to more sophisticated inventory planning and replenishment requirements. Stock planners are often confronted with tell-tale signs that they need further automation to improve demand forecasting, optimise stock levels and automate replenishment tasks. Are you one of these people? Here are eight warning signs to help you decide…

 

1: Your demand forecasting is too simplistic

Inventory planning on paperEffective inventory planning and control begins with accurate demand forecasting software. If your actual demand is often way above or below your predictions then the spreadsheets or ERP you’re using could simply be inadequate. It’s very probable that you either use a basic moving average formula to calculate demand (historical average demand over x months/ x months) or simple mathematical forecasting techniques. Either way, both methods will fall down unless they take into account the product lifecycle stage of every item in your portfolio.

This is because the demand pattern of items in their growth phase of the product lifecycle will be different to those at maturity or in decline. During ‘growth’, items see an increase in demand, at ‘maturity’ demand usually remains steady, becoming more erratic as it reaches ‘decline’, as sales become less consistent.

The ‘demand type’ of a product determines the best statistical algorithms to use for forecasting e.g some algorithms are better for erratic demand types, whilst others give more accurate results for more stable demand. Basic forecasting calculations cannot take this into account.

Read our blog post on how to calculate your demand forecasting accuracy for further information.

 

2: You’re unable to forecast seasonality or deal with volatile demand fluctuations

If you struggle to produce accurate forecasts for seasonal products or SKUs where demand radically fluctuates up and down, it’s time for an inventory planning overhaul! Every business wants to capitalise on busy sales periods and running out of key inventory items before the end of the season can dent sales. At the same time, being left with excess stock until the following season can tie up important capital.

It’s critical that inventory systems make forecast adjustments for demand variables, such as seasonality, trends and promotions, on top of your base demand.

 

Excess stock3: Your stock levels are growing, inventory turnover is slipping

If stock in your warehouse is beginning to pile up, alarm bells should be ringing about your current inventory planning and replenishment processes.

You should be able to segment your stock into three types: healthy stock, excess stock and obsolete stock. Obviously you want more of the first and less of the latter two. If you’re over ordering items that aren’t selling, excess stock will soon mount up and you’ll see your inventory turnover KPI move in the wrong direction. Capital tied up in stock can also be bad for your overall business, affecting carrying costs, liquidity and cash flow.

 

4: Your customer service levels are highly variable

How do you measure your warehouse’s ability to fulfil customer orders? No matter whether you use a fill rate, service level, service index or perfect order percentage KPI, if they’re not consistently high then it’s time to investigate why. Often an inability to fulfil orders is due to stockouts which can link back to poor forecasting or inadequate inventory replenishment processes.

 

5. There’s a growing trend of lost sales or accounts

Stock availability issues can often lead to a drop in sales. If you identify a link between the two, it’s worth considering solutions to the root cause – poor inventory planning.
You may be tracking the obvious consequences of stockouts, such as abandoned online baskets or a decline in sales numbers, but, at the same time, don’t forget to monitor longer-term signs. For example, if you continually fail to fulfil customer demand, you could see customers moving to competitors for good, or find you lose important customer accounts due to an ability to realise orders on time.

 

Guide to Inventory Health Self-Assessment
 

6. You are constantly fire-fighting

When you and your inventory planners are constantly fire-fighting, it can be tough to achieve your targets, or have time for strategic planning. Dealing with backorders and expediting replenishment orders is inefficient and costly for any business. A smarter approach is to address the cause of problem.

 

7. Inventory replenishment is time-consuming

If you’re using manual processes to reorder stock this is a certain indication that it’s time to consider upgrading to automated inventory replenishment. Processing and checking every purchase Automated replenishment helps supplier managementorder manually is time-consuming. Plus it’s almost impossible to reduce your order cycle times (the time between placing each order), which means you’ll be ordering less frequently and have more money tied-up in stock.

 

8. You’re unable to manage varying supplier lead times

Do you struggle to account for your individual supplier’s lead times and reorder parameters when placing orders? For example, do you often get caught out by annual shutdowns, busy periods or holidays such as Chinese New Year? Or do you find it hard to keep track of min/max order quantities and contracted reorder frequencies? If these challenges increase your risk of stockouts and lead to inefficient replenishment practices – it’s time to talk about inventory replenishment automation!

 

Know your inventory planning and replenishment limits!

Many small and medium-sized businesses use ERPs or spreadsheets for their inventory planning, but most will agree they have limitations. Most ERP systems are ideal for tracking inventory and monitoring stock levels. But when it comes to inventory optimisation functionality, such as advanced demand forecasting, stock optimisation and automated replenishment – they lack the capabilities. These inventory control and planning processes therefore end up being executed in spreadsheets, which is time-consuming, can lead to human error and can become unmanageable as product portfolios expand.

If you or your inventory management team are experiencing the above challenges it may be time to consider inventory planning software, such as EazyStock.

EazyStock is easy to implement – the inventory optimisation software simply plugs-into your ERP. It then removes the need for manual inventory planning in spreadsheets, allowing you to automate and speed up forecasting, stock management and purchasing activities. Armed with better stock planning tools, you and your team will have more time to think strategically and focus on improving your efficiency and profitability.

If you’d like to know more, call us on 0121 312 2992 or contact us here.

 

ebook - The SMBs Guide to Inventory Optimisation Software