Another look at estimators for intermittent demand

In this paper we focus on forecasting for intermittent demand data. We propose a new aggregation framework for intermittent demand forecasting that performs aggregation over the demand volumes, in contrast to the standard framework that employs temporal (over time) aggregation. To achieve this we construct a transformed time series, the inverse intermittent demand series. The new algorithm is expected to work best on erratic and lumpy demand, as a result of the variance reduction of the non-zero demands. The improvement in forecasting performance is empirically demonstrated through an extensive evaluation in more than 8,000 time series of two well-researched spare parts data sets from the automotive and defence sectors. Furthermore, a simulation is performed so as to provide a stock-control evaluation. The proposed framework could find popularity among practitioners given its suitability when dealing with clump sizes. As such it could be used in conjunction with existing popular forecasting methods for intermittent demand as an exception handling mechanism when certain types of demand are observed

Effective forecasting for supply-chain planning: an empirical evaluation and strategies for improvement

Demand forecasting is a crucial aspect of the planning process in supply-chain companies. The most common approach to forecasting demand in these companies involves the use of a simple univariate statistical method to produce a forecast and the subsequent judgmental adjustment of this by the company's demand planners to take into account market intelligence relating to any exceptional circumstances expected over the planning horizon. Based on four company case studies, which included collecting more than 12,000 forecasts and outcomes, this paper examines: i) the extent to which the judgmental adjustments led to improvements in accuracy, ii) the extent to which the adjustments were biased and inefficient, iii) the circumstances where adjustments were detrimental or beneficial, and iv) methods that could lead to greater levels of accuracy. It was found that the judgmentally adjusted forecasts were both biased and inefficient. In particular, market intelligence that was expected to have a positive impact on demand was used far less effectively than intelligence suggesting a negative impact. The paper goes on to propose a set of improvements that could be applied to the forecasting processes in the companies and to the forecasting software that is used in these processes

On intermittent demand model optimisation and selection

Intermittent demand time series involve items that are requested infrequently, resulting in sporadic demand. Croston's method and its variants have been proposed in the literature to address this forecasting problem. Recently other novel methods have appeared. Although the literature provides guidance on the suggested range for model parameters, a consistent and valid optimisation methodology is lacking. Growing evidence in the literature points against the use of conventional accuracy error metrics for model evaluation for intermittent demand time series. Consequently these may be inappropriate for parameter or model selection. This paper contributes to the discussion by evaluating a series of conventional time series error metrics, along with two novel ones for parameter optimisation for intermittent demand methods. The proposed metrics are found to not only perform best, but also provide consistent parameters with the literature, in contrast to conventional metrics. Furthermore, this work validates that employing different parameters for smoothing the non-zero demand and the inter-demand intervals of Croston's method and its variants is beneficial. The evaluated error metrics are considered for automatic model selection for each time series. Although they are found to perform similarly to theory driven model selection schemes, they fail to outperform single models substantially. These findings are validated using both out-of-sample forecast evaluation and inventory simulations

Demand uncertainty and lot sizing in manufacturing systems: the effects of forecasting errors and mis-specification

This paper proposes a methodology for examining the effect of demand uncertainty and forecast error on lot sizing methods, unit costs and customer service levels in MRP type manufacturing systems. A number of cost structures were considered which depend on the expected time between orders. A simple two-level MRP system where the product is manufactured for stock was then simulated. Stochastic demand for the final product was generated by two commonly occurring processes and with different variances. Various lot sizing rules were then used to determine the amount of product made and the amount of materials bought in. The results confirm earlier research that the behaviour of lot sizing rules is quite different when there is uncertainty in demand compared to the situation of perfect foresight of demand. The best lot sizing rules for the deterministic situation are the worst whenever there is uncertainty in demand. In addition the choice of lot sizing rule between ‘good’ rules such as the EOQ turns out to be relatively less important in reducing unit cost compared to improving forecasting accuracy whatever the cost structure. The effect of demand uncertainty on unit cost for a given service level increases exponentially as the uncertainty in the demand data increases. The paper also shows how the value of improved forecasting can be analysed by examining the effects of different sizes of forecast error in addition to demand uncertainty. In those manufacturing problems with high forecast error variance, improved forecast accuracy should lead to substantial percentage improvements in unit costs

Judgement and supply chain dynamics

Forecasting demand at the individual stock-keeping-unit (SKU) level often necessitates the use of statistical methods, such as exponential smoothing. In some organizations, however, statistical forecasts will be subject to judgemental adjustments by managers. Although a number of empirical and ‘laboratory’ studies have been performed in this area, no formal OR modelling has been conducted to offer insights into the impact such adjustments may have on supply chain performance and the potential development of mitigation mechanisms. This is because of the associated dynamic complexity and the situation-specific nature of the problem at hand. In conjunction with appropriate stock control rules, demand forecasts help decide how much to order. It is a common practice that replenishment orders may also be subject to judgemental intervention, adding further to the dynamic system complexity and interdependence. The system dynamics (SD) modelling method can help advance knowledge in this area, where mathematical modelling cannot accommodate the associated complexity. This study, which constitutes part of a UK government funded (EPSRC) project, uses SD models to evaluate the effects of forecasting and ordering adjustments for a wide set of scenarios involving: three different inventory policies; seven different (combinations of) points of intervention; and four different (combinations of) types of judgmental intervention (optimistic and pessimistic). The results enable insights to be gained into the performance of the entire supply chain. An agenda for further research concludes the paper

Advancing Cost-Effective Readiness by Improving the Supply Chain Management of Sparse, Intermittently-Demanded Parts

Many firms generate revenue by successfully operating machines such as welding robots, rental cars, aircraft, hotel rooms, amusement park attractions, etc. It is critical that these revenue-generating machines be operational according to the firm s target or requirement; thus, assuring sustained revenue generation for the firm. Machines can and do fail, and in many cases, restoring the downed machine requires spare part(s), which are typically managed by the supply chain. The scope of this research is on the supply chain management of the very sparse, intermittently-demanded spare parts. These parts are especially difficult to manage because they have little to no lead time demand; thus, modeling via a Poisson process is not viable. The first area of our research develops two new frameworks to improve the supply chain manager s stock policy on these parts. The stock polices are tested via case studies on the A-10C attack aircraft and B1 bomber fleets. Results show the AF could save $10M/year on the A10 and improve support to the B1 without increasing inventory. The second area of our research develops a framework to integrate the supply chain processes that generate these service parts. With the integrated framework, we establish two new forward-looking metrics. We show examples how these forward-looking metrics can advance the supply chain manager s desire to know what proactive decisions to make to improve his/her supply chain for the good of the firm

Forecasting Demand for Optimal Inventory with Long Lead Times: An Automotive Aftermarket Case Study

Accuracy in predicting customer demand is essential to building an economic inventory policy under periodic review, long lead-time, and a target fill rate. This study uses inventory and customer service level as a stock control metric to evaluate the forecast accuracy of different simple to more complex predictive analytical techniques. We show how traditional forecast error measures are inappropriate for inventory control, despite their consistent usage in many studies, by evaluating demand forecast performance dynamically with customer service level as a stock control metric that includes inventory holdings costs, stock out costs, and fill rate service levels. A second contribution includes evaluating the utility of introducing more complexity into the forecasting process for an automotive aftermarket parts manufacturer and the superior inventory control results using the Prais-Winsten, an econometric method, for non-intermittent demand forecasting with long-lead times. This study will add to the limited case study research on demand forecasting under long lead times using stock control metrics, dynamic model updating, and the Prais-Winsten method for inventory control