Forecasting of intermittent demand: A Thesis submitted for the degree of Doctor of Philosophy, Business School, Buckinghamshire Chilterns University College, Brunel University July 2001

This thesis explores forecasting for intermittent demand requirements. Intermittent demand occurs at random, with some time periods showing no demand. In addition, demand, when it occurs, may not be for a single unit or a constant size. Consequently, intermittent demand creates significant problems in the supply and manufacturing environment as far as forecasting and inventory control are concerned. A certain confusion is shared amongst academics and practitioners about how intermittent demand (or indeed any other demand pattern that cannot be reasonably represented by the normal distribution) is defined. As such, we first construct a framework that aims at facilitating the conceptual categorisation of what is termed, for the purposes of this research, “non-normal” demand patterns. Croston (1972) proposed a method according to which intermittent demand estimates can be built from constituent elements, namely the demand size and inter-demand interval. The method has been claimed to provide unbiased estimates and it is regarded as the “standard” approach to dealing with intermittence. In this thesis we show that Croston’s method is biased. The bias is quantified and two new estimation procedures are developed based on Croston’s concept of considering both demand sizes and inter-demand intervals. Consequently the issue of variability of the intermittent demand estimates is explored and finally Mean Square Error (MSE) expressions are derived for all the methods discussed in the thesis. The issue of categorisation of the demand patterns has not received sufficient academic attention thus far, even though, from the practitioner’s standpoint it is appealing to switch from one estimator to the other according to the characteristics of the demand series under concern. Algebraic comparisons of MSE expressions result in universally applicable (and theoretically coherent) categorisation rules, based on which, “non-normal” demand patterns can be defined and estimators be selected. All theoretical findings are checked via simulation on theoretically generated demand data. The data is generated upon the same assumptions considered in the theoretical part of the thesis. Finally, results are generated using a large sample of empirical data. Appropriate accuracy measures are selected to assess the forecasting accuracy performance of the estimation procedures discussed in the thesis. Moreover, it is recognised that improvements in forecasting accuracy are of little practical value unless they are translated to an increased customer service level and/or reduced inventory cost. In consequence, an inventory control system is specified and the inventory control performance of the estimators is also assessed on the real data. The system is of the periodic order-up-to-level nature. The empirical results confirm the practical validity and utility of all our theoretical claims and demonstrate the benefits gained when Croston’s method is replaced by an estimator developed during this research, the Approximation method

Base-stock policies with reservations

All intensively studied and widely applied inventory control policies satisfy demand in accordance with the First-Come-First-Served (FCFS) rule, whether this demand is in backorder or not. Interestingly, this rule is sub-optimal when the fill-rate is constrained or when the backorder cost structure includes fixed costs per backorder and costs per backorder per unit time. In this paper we study the degree of sub-optimality of the FCFS rule for inventory systems controlled by the well-known base-stock policy. As an alternative to the FCFS rule, we propose and analyze a class of generalized base-stock policies that reserve some maximum number of items in stock for future demands, even if backorders exist. Our analytic results and numerical investigations show that such alternative stock reservation policies are indeed very simple and considerably improve either the fillrate or reduce the total cost, without having much effect on the backorder level

Forecasting of compound Erlang demand

Intermittent demand items dominate service and repair inventories in many industries and they are known to be the source of dramatic inefficiencies in the defence sector. However, research in forecasting such items has been limited. Previous work in this area has been developed upon the assumption of a Bernoulli or a Poisson demand arrival process. Nevertheless, intermittent demand patterns may often deviate from the memory-less assumption. In this work we extend analytically previous important results to model intermittent demand based on a compound Erlang process, and we provide a comprehensive categorisation scheme to be used for forecasting purposes. In a numerical investigation we assess the benefit of departing from the memory-less assumption and we provide insights into how the degree of determinism inherent in the process affects forecast accuracy. Operationalised suggestions are offered to managers and software manufacturers dealing with intermittent demand items

Forecasting intermittent inventory demands: simple parametric methods vs. bootstrapping

Although intermittent demand items dominate service and repair parts inventories in many industries, research in forecasting such items has been limited. A critical research question is whether one should make point forecasts of the mean and variance of intermittent demand with a simple parametric method such as simple exponential smoothing or else employ some form of bootstrapping to simulate an entire distribution of demand during lead time. The aim of this work is to answer that question by evaluating the effects of forecasting on stock control performance in more than 7,000 demand series. Tradeoffs between inventory investment and customer service show that simple parametric methods perform well, and it is questionable whether bootstrapping is worth the added complexity

Reliability analysis for automobile engines: conditional inference trees

The reliability model with covariates for machinery parts has been extensively studied by the proportional hazards model (PHM) and its variants. However, it is not straightforward to provide business recommendations based on the results of the PHM. We use a novel method, namely the Conditional Inference Tree, to conduct the reliability analysis for the automobile engines data, provided by a UK fleet company. We find that the reliability of automobile engines is significantly related to the vehicle age, early failure, and repair history. Our tree-structured model can be easily interpreted, and tangible business recommendations are provided for the fleet management and maintenance

Forecasting spare part demand with installed base information: A review

The classical spare part demand forecasting literature studies methods for forecasting intermittent demand. However, the majority of these methods do not consider the underlying demand-generating factors. The demand for spare parts originates from the replacement of parts in the installed base of machines, either preventively or upon breakdown of the part. This information from service operations, which we refer to as installed base information, can be used to forecast the future demand for spare parts. This paper reviews the literature on the use of such installed base information for spare part demand forecasting in order to asses (1) what type of installed base information can be useful; (2) how this information can be used to derive forecasts; (3) the value of using installed base information to improve forecasting; and (4) the limits of the existing methods. This serves as motivation for future research

The Repair Kit Problem with positive replenishment lead times and fixed ordering costs

The Repair Kit Problem (RKP) concerns the determination of a set of items taken by a service engineer to perform on-site product support. Such a set is called a kit. Models developed in the literature have always ignored the lead times associated with delivering items to replenish the kit, thereby limiting the practical relevance of the proposed solutions. Motivated by a real life case, we develop a model with positive lead times to control the replenishment quantities of the items in the kit, and study the performance of (s, S) policies under a service objective. The choice for (s, S) policies is made in order to accommodate fixed ordering costs. We present a method to calculate job fill rates with exact expressions, and discuss a heuristic approach to optimize the reorder level and order-up-to level for each item in the kit. The empirical utility of the model is assessed on real world data from an equipment manufacturer and useful insights are offered to after-sales managers

Demand forecasting by temporal aggregation

Demand forecasting performance is subject to the uncertainty underlying the time series an organization is dealing with. There are many approaches that may be used to reduce uncertainty and thus to improve forecasting performance. One intuitively appealing such approach is to aggregate demand in lower-frequency “time buckets.” The approach under concern is termed to as temporal aggregation, and in this article, we investigate its impact on forecasting performance. We assume that the nonaggregated demand follows either a moving average process of order one or a first-order autoregressive process and a single exponential smoothing (SES) procedure is used to forecast demand. These demand processes are often encountered in practice and SES is one of the standard estimators used in industry. Theoretical mean-squared error expressions are derived for the aggregated and nonaggregated demand to contrast the relevant forecasting performances. The theoretical analysis is supported by an extensive numerical investigation and experimentation with an empirical dataset. The results indicate that performance improvements achieved through the aggregation approach are a function of the aggregation level, the smoothing constant, and the process parameters. Valuable insights are offered to practitioners and the article closes with an agenda for further research in this area

'Soft' supplier management related issues: An empirical investigation

A research project recently undertaken by the authors focused on supplier management related issues and the extent to which they are shaped by the organizational culture and structure. The project was conducted in the Hospitality industry and employed an inductive methodological approach in order to collect rich information from six organizations. The organizations represent different structuring models as well as distinct underlying culture-related principles. The findings challenge the assumption regarding beneficial universal applicability of many practices such as ‘Purchasing Consortia’, ‘Service Level Agreements’ and the establishment of long-term relationships. Our analysis also suggests that organizational culture and structure are reflected on the supplier management approaches adopted by the organizations under consideration