Inventory replenishment planning

The key to effective inventory replenishment planning

Mark Chapman

3 min read

The key to unlocking effective inventory replenishment planning

UK businesses across the supply chain, from manufacturers to retailers, are under constant pressure to improve operational efficiency and service levels. Customers want their goods without delay, meaning order lead times are increasingly important in their purchasing decision. Businesses therefore need top class inventory planning and order management processes in place, to ensure the speedy replenishment of warehouse goods.

Below we look at two ways you can improve your replenishment planning processes to optimise inventory levels across your supply chain. These industry secrets go beyond basic inventory replenishment methods, and focus on how managing supply and demand variables can transform how you approach this important aspect of supply chain planning.

Looking ahead when inventory replenishment planning

Robust inventory demand forecasting

Behind every good inventory replenishment strategy is an accurate demand forecasting machine. This functionality can often be found within your enterprise resource management (ERP) or warehouse management system (WMS) and it uses previous sales or customer demand data to calculate future reordering requirements.However, simply basing forecasts on previous demand is a very risky business. Our blog post on inventory demand forecasting techniques explains why. Instead smart replenishment planning teams use more sophisticated forecasting tools that account for the following variables:

By adding these to your basic forecasts, you can improve their accuracy, which, in turn, will inform your reordering activity. This makes inventory replenishment planning across your supply chain a much smoother process.

But remember, the demand for a SKU can change on a daily basis e.g a product can go from being a fast- moving item during a seasonal peak, to having virtually no demand overnight. This means you need to update your forecasts and re-assess demand variables on a regular basis. To do this effectively you may need specialist demand forecasting software. Read our blog post on forecasting and replenishment for more details.

EazyStock Software Demand Forecasting

Reducing the risk of variable supplier lead times

Supplier lead times can make or break your ability to replenish your warehouse effectively and fulfil orders on time. Unfortunately, even the most reliable suppliers will have unforeseen disruptions in delivery. And, if these disruptions affect your service levels and stock availability, you may experience a negative impact on customer loyalty.

Here are two ways to account for supplier lead times when calculating your inventory replenishment needs:Including suppliers when replenishment planning

1. Carry an adequate amount of safety stock. This helps mitigate the risk associated with supplier lead time variability. You can set safety stock according many different rules, including:

  • Using ABC analysis e.g carry more safety stock of your most important stock items, than those that are less valuable to the business.
  • By identifying inventory with a high turnover ratio and ensuring more safety stock for these faster-moving items.
  • Based on lead times e.g holding more safety stock for suppliers with longer lead times than those who can deliver the same day.

2. Sometimes supplier delays may be simply overlooked by your replenishment team, even though they occur every year. For example, Chinese New Year in the Far East, or summer shutdowns in Italy are annual events, often causing unnecessary interruptions to supply. These can be easily overcome by adding the known lead time delay to your reorder point and or reorder quantity calculations, so the interruption is accounted for.

EazyStock’s supplier order management functionality can do just that. You simply create a calendar for each supplier and add the shutdown dates. The system automatically adjusts the lead times and order points for all items from this supplier, to cover the time when they are ‘out-of-office’. EazyStock will also trigger an order early enough for your supplier to be able to fulfil it before they close, so you’ll have enough stock, despite the disruption.

EazyStock Software Supplier Management

Inventory replenishment software

Planning your stock replenishment needs is a tricky business. It’s a balancing act to order the right levels of the right stock to cover your demand, without risking a build-up of excess and obsolete items. At the same time supplier lead times need to be factored into reorder point and reorder quantity calculations so there’s always enough stock to fulfil customer orders.

You’ll no doubt have noticed that the two inventory replenishment planning techniques above may be challenging to carry out in spreadsheets. Even more advanced WMS or ERP systems may also find such calculations a strain. But the fact is, ineffective inventory planning and replenishment can disrupt your supply chain and erode profit margins. So, it’s therefore worthwhile taking the time to review how you take supply and demand variables into account when setting your replenishment parameters.

If you think it’s time to investigate how inventory replenishment software could assist your business, contact EazyStock for a free demo or call 0121 312 2992.


Whitepaper - How to Overcome 3 Common Inventory Replenishment Challenges


Mark Chapman

3 min read

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