Streamlining Inventory Management: A Case Study on BHS Corrugated’s Industry 4.0 Transformation

Accurate forecasting is critical for the success of any supply chain management operation. Without it, businesses are vulnerable to demand volatility, overstocking, stock outs, and lost sales. However, there’s no one-size-fits-all approach to forecasting. It involves a combination of tools, processes, and human judgment to predict future demand patterns. In this article, we’ll discuss the basics of forecasting in supply chain management and some best practices for improving inventory accuracy.

1. The Importance of Forecasting in Supply Chain Management

• Benefits of accurate forecasting
• Consequences of inaccurate forecasting

2. Factors to Consider in Forecasting

• Customer history and communication
• Market and product complexity
• Demand classification
• Sales teams and corporate executives vs. accounting

3. Best Practices for Forecasting

• Simplicity is key
• Short-term forecasting vs long-term forecasting
• Accuracy measurement and adjustment
• Aggregated forecasting vs granular forecasting
• Collaborating with customers
• Keep up-to-date with news and economic issues

4. Forecasting Models and Tools

• Holt’s and Winter’s models
• Decision trees
• Markov chains
• Monte Carlo simulation

5. Range-based thinking

• The importance of range-based thinking in forecasting
• Proactive mitigation planning

6. Conclusion

• Importance of continuous improvement in forecasting practices
• Final thoughts

Factors to Consider in Forecasting

Customer history and communication

Customer history and communication play an essential role in forecasting accuracy in supply chain management. Here are some key points to consider:

• Past sales history: Historical performance can provide valuable insights into their future capabilities. Analyzing past performance data can help to identify trends and patterns that can be used to predict future performance.
• Communication: Good communication between a business and its customers is crucial for accurate forecasting. Customer’s need to be informed of changes in demand and any potential disruptions in the supply chain. Similarly, businesses need to be aware of any challenges or changes on the customer side. This requires ongoing collaboration and an open line of communication between both parties.

By taking customer history and communication into account when forecasting, businesses can better anticipate potential supply chain disruptions and adjust their plans accordingly. This can help to minimize inventory costs, reduce stock outs, and ensure customer satisfaction.

Market and product complexity

Forecasting accuracy is heavily influenced by market and product complexity. As markets become more complex, featuring many products or intricate supply chains, it can be difficult to predict consumer demand accurately.

It is important to note that forecasting is not a perfect science. Forecasts are essentially educated guesses based on a variety of factors, some of which are beyond our control. As a result, inaccuracies will arise, but the primary goal of forecasting is to anticipate potential outcomes and plan accordingly.

Forecasting sets expectations, which can help supply chain managers make informed decisions and respond quickly when things don’t go according to plan. Even the most accurate forecasts will still encounter unforeseeable events that can disrupt the supply chain. Therefore, it is essential to create systems to ensure things go as planned and identify and correct any issues that arise.

Ultimately, the level of complexity in forecasting will depend on a company’s products, market, and position in the supply chain. But by considering all relevant factors, including supplier history and communication, market and product complexity, and customer demand volatility, supply chain managers can make informed decisions and establish effective systems to optimize their operations.

Demand classification

Demand classification is a crucial aspect of forecasting in supply chain management. It involves categorizing demand patterns for different products or SKUs, which helps to identify the level of forecasting difficulty and the appropriate forecasting techniques to use. Generally, demand patterns can be classified into four types: constant, trend, seasonality, and irregular.

To classify demand patterns, you need to analyze the historical sales data of each product or SKU. Once you have identified the pattern, you can use it to forecast future demand. For example, if a product has a constant demand pattern, you can use a simple moving average technique to forecast future demand. On the other hand, if a product has a seasonal demand pattern, you can use a seasonal forecasting technique such as seasonal exponential smoothing to forecast future demand.

It’s important to classify demand patterns for each product or SKU because those with less variation will be easier to predict. Products with sufficient revenue and easy-to-forecast demand can be made to stock. Conversely, products with extreme variation in demand may require higher safety stock to fulfill demand, leading to increased inventory costs. For rare items that are difficult to forecast, companies may choose to offer full lead times only.

When attempting to understand buyer behaviors, it is essential to take into account all potential variables that could sway a consumer’s decision about the product. This can include external factors such as climate conditions and internal ones like quality or price point. Besides forecasting individual items (SKUs), businesses should also look at broader market segments for an overall snapshot of demand trends. Doing so will ensure better accuracy when predicting what consumers are likely to purchase next.

Again, forecasting does not guarantee perfection, and there will always be errors to some degree. However, the main goal of forecasting is to consider all possible scenarios before they happen, set expectations, and have systems in place to see when things aren’t going well and get back on track. By classifying demand patterns and using appropriate forecasting techniques, companies can improve their supply chain planning and management, leading to better customer satisfaction and overall business success.

Though forecasting cannot guarantee absolute accuracy, its ultimate purpose is to anticipate potential outcomes, create expectations and devise systems that can quickly identify when something goes wrong. By analyzing demand patterns and leveraging the right forecasting methods, companies can optimize their supply chain planning while simultaneously improving customer satisfaction – ultimately aiding in achieving overall business success.

Sales teams and corporate executives vs. accounting

Demand classification is a crucial aspect of forecasting in supply chain management. It involves categorizing demand patterns for different products or SKUs, which helps to identify the level of forecasting difficulty and the appropriate forecasting techniques to use. Generally, demand patterns can be classified into four types: constant, trend, seasonality, and irregular.

To classify demand patterns, you need to analyze the historical sales data of each product or SKU. Once you have identified the pattern, you can use it to forecast future demand. For example, if a product has a constant demand pattern, you can use a simple moving average technique to forecast future demand. On the other hand, if a product has a seasonal demand pattern, you can use a seasonal forecasting technique such as seasonal exponential smoothing to forecast future demand.

Forecasting Models and Tools

Holt’s and Winter’s model

Holt’s and Winter’s model is a popular method of forecasting that is based on time series data. This model is particularly useful for forecasting trends in demand and is often used in the consumer goods industry. The model has two components: trend and seasonal. The trend component is used to forecast the long-term behavior of the data, while the seasonal component is used to forecast the seasonal variations in the data. The two components are combined to generate the final forecast.

Decision trees

Decision trees are a type of machine learning model that is used for classification and regression analysis. They can be used for forecasting by creating a tree-like model of decisions and outcomes. Each node in the tree represents a decision or a feature of the data, and the branches represent possible outcomes or classifications. Decision trees are particularly useful when there are a large number of potential factors that may influence the forecast, as they can help identify the most important factors and prioritize them accordingly.

Markov chains

Markov chains are a mathematical model that can be used to forecast future events based on current conditions. They are particularly useful for forecasting demand for products that have limited availability, such as airline tickets or hotel rooms. Markov chains work by modeling the probability of a customer buying a product at a given time, based on their previous purchasing behavior.

Monte Carlo simulation

Monte Carlo simulation is a statistical technique that can be used to generate forecasts by simulating possible future scenarios. This method is particularly useful for forecasting demand for products that are subject to significant variability or uncertainty, such as commodities or weather-dependent products. Monte Carlo simulation works by generating a large number of possible scenarios based on historical data and then calculating the probability of each scenario occurring.

Conclusion

To summarize, the basics of forecasting in supply chain management include:

• Understanding the basics of demand planning: This includes analyzing demand patterns, understanding market and product complexity, and classifying demand patterns for better forecasting accuracy.
• Best practices for forecasting: These include keeping it simple, distinguishing between short-term and long-term forecasting, measuring and adjusting for accuracy, using aggregated vs. granular forecasting, collaborating with customers, and staying up-to-date with news and economic issues.
• Importance of forecasting models and tools: Popular models include Holt’s and Winters’ model, decision trees, Markov chains, and Monte Carlo simulation.
• Range-based thinking and proactive mitigation planning: This involves thinking in terms of a weighted range of potential outcomes rather than an exact number, understanding the outcomes of being wrong, and planning proactively for mitigation.

Importance of continuous improvement in forecasting practices

Continuous improvement is crucial in forecasting as supply chain dynamics and market conditions change rapidly. Forecasts must be continually evaluated, refined, and adjusted to ensure accuracy and effectiveness. A continuous improvement approach involves analyzing forecast results, identifying areas for improvement, implementing process improvements, and measuring the impact of those changes.

Final thoughts

Mastering the basics of forecasting in supply chain management is essential for effective planning and decision-making. It requires a combination of knowledge, skill, and experience in analyzing demand patterns, selecting the appropriate forecasting models and tools, and proactive range-based thinking. Continuous improvement is critical to maintaining forecasting accuracy and ensuring supply chain success. With the right approach, organizations can stay ahead of the curve and anticipate potential changes in demand or supply to ensure long-term sustainability.