Managing Intermittent Demand
Managing Intermittent Demand
Managing
Intermittent
Demand
Managing Intermittent Demand
Torben Engelmeyer
Managing Intermittent
Demand
Torben Engelmeyer
Wuppertal, Germany
Springer Gabler
© Springer Fachmedien Wiesbaden 2016
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List of Tables XI
1 Introduction 1
2 Inventory Management 7
2.1 Supply Chain Performance Measurement . . . . . . . . . . . 7
2.2 Relevant Costs . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Inventory Policies . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.1 Stochastic Inventory Models . . . . . . . . . . . . . . 20
2.3.2 Determination of the Order-Up-To-Level S . . . . . 20
2.3.3 Determination of the Reorder Point s . . . . . . . . 22
4 Demand Classification 63
4.1 ABC Classification . . . . . . . . . . . . . . . . . . . . . . . 63
4.2 Forecast-Based Classification . . . . . . . . . . . . . . . . . 66
4.3 Multi-Criteria Inventory Classification . . . . . . . . . . . . 70
II Empirical Analysis 73
5 Simulation Design 75
5.1 Data Description and Preparation . . . . . . . . . . . . . . 75
5.2 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.3 Simulation Procedure . . . . . . . . . . . . . . . . . . . . . 79
5.4 Implementation . . . . . . . . . . . . . . . . . . . . . . . . . 83
6 Results 87
6.1 Forecasts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.2 Inventory Simulation . . . . . . . . . . . . . . . . . . . . . . 91
6.2.1 α-Service Level Target . . . . . . . . . . . . . . . . . 92
6.2.2 β-Service Level Target . . . . . . . . . . . . . . . . . 99
6.3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7 Conclusion 109
A Appendix 113
Bibliography 149
List of Figures
η Inventory turnover
μ+
Y
Expectation of positive demands
εt Error terms
ax Selection vector
Ci Clustering criteria
L Lead time
Px Set of all paths, where the sum of the weights of the visited vertices
equals x
Q Order quantity
r Reorder interval
S Order-up-to level
s Reorder point
ui Return of asset i
The past years of logistic management have been studded with buzzwords
trying to condense the achievements and problems of their times. Just-in-
time production changed the view on inventories from assets, which convert
to cash, to pure cost drivers. With an increasing availability of data, con-
cepts like Efficient Consumer Response and Predictive Analytics resulted
in the need for optimized decisions based on uncertain demand informa-
tion. These trends show that inventory management is a crucial function
of logistics, and it is a tautology that optimal inventory decisions are based
on optimal forecasts. But this frequently leads to problems. On the one
hand, forecasts are calculated using sophisticated methods gathering all
the features of a demand series in order to produce the most accurate fore-
casts. On the other hand, there is a wide range of stochastic inventory
models for all circumstances which come with rigid stochastic assumptions
like gaussian or gamma distributed lead time demand.
Taken individually, both approaches are optimal and no problems may re-
sult, if all assumptions along the method chain are met. The problem arises
with the combination of the forecast and inventory management methods
during the sales and operation planning process. Forecast method selection
depends on statistical error measures and does not consider the resulting
supply chain performance. The stochastic inventory model reduces the
forecast to the first two moments and therefore, most information remains
unused when the reorder levels are optimized. Additionally, assuming con-
tinuous demand is always a simplifying assumption which only holds for a
small subset of Stock Keeping Units (SKUs). Johnston and Boylan (2003)
stated that about 75% of all items across most branches move no more
than six times a year and therefore are referred to as intermittent. Those
intermittent demand SKUs collectively sum up to about 60% of inventory
investments and lead to theoretical inconsistencies between the methods
used in the sales and operations planning process.
After this Chapter 3 presents forecast methods which are suitable for in-
termittent demand series. It starts with the fundamentals of time series
analysis and a description of the available forecast methods, but this chap-
ter mainly deals with integer-valued autoregressive processes. Those have
been applied in finance and physics, but there is no record of previous
connections of integer-valued autoregressive processes and inventory man-
agement. Additionally, the Markov Chain simulation technique in order to
aggregate the future PMFs is proposed at the end of this chapter.
The empirical part of this study begins with the description of the data
and the simulation design (Chapter 5) which includes the application of
all methods proposed in the previous chapters. After this, the results are
described in Chapter 6. It is divided into four sections. First, the re-
sults of the forecast performance by means of statistical error measures
are presented, and then the next two sections of the chapter deal with the
inventory performance of all the methods for the α- and β-service level tar-
gets, respectively. The last section of this chapter summarizes the results.
This study closes with a conclusion and outlook in Chapter 7.
Part I
This chapter is divided into three parts. Section 2.1 deals with the measure-
ment of the supply chain performance. Thus, it describes what is meant
by fulfilling the customer’s needs. After this, Section 2.2 gives an overview
of the relevant costs, their relationships, and how they can be estimated
based on a company’s balance sheet. The last and main part of this chapter
introduces different inventory policies and the decision variables which can
be set in order to fulfill the customer’s needs at minimal costs. It focuses
on stochastic inventory models and methods to find an optimal inventory
policy.
the inventory turnover. All measures are widely used in theory and practice
and feature two different views of what is meant by supply chain perfor-
mance. The α- and the β-service measure the performance from the cus-
tomer’s perspective whereas the inventory turnover is a technical measure
to describe the supply chain performance in sense of capital efficiency. This
section presents these three performance indicators and gives an example
to state the properties of those views.
Inventory levels
30
20
Quantity
10
-10
Week 1 Week 2 Week 3 Week 4 Week 5
Figure 2.1: Inventory levels of one SKU over five weeks
Table 2.1 lists the weekly aggregated data of Figure 2.1. The demand is
aggregated as the sum of sold pieces within a week. The second row lists
the inventory level at the end of each week. Therefore, the inventory level
at week 0 is the starting inventory level of the first week. The inventory
level in each period is equal to the inventory level of the previous week plus
deliveries of the current week minus the demand during the current week.
For example, the inventory level at the end of week 3 is 5, because it starts
with −10, the demand is 5 and a quantity 20 is delivered at the beginning
of the week ((−10) − 5 + 20 = 5). In this setup it is assumed that customer
demands which cannot be fulfilled are backordered, which means the cus-
tomer will wait for the next delivery if the SKU is understocked. This
assumption will not hold in every case, but if one considers the inventory
of an online store, this might be realistic. The assumption that unsatis-
fied customers will wait for the next delivery reduces the complexity and
is therefore well suited for an introductory example.
α-Service Level
α = P (yt ≤ It ) , (2.1)
10 2 Inventory Management
β-Service Level
In contrast to the customer focus of the α-service, the β-service level focuses
on delivered quantities. It measures the share of demand which could be
delivered directly from stock with no delay. Because of that the β-service
is usually used as a target for a warehouse. It is given by:
where E(yt |yt > It ) is the conditional expectation of the demand which
exceeds the current inventory level. For the given example β equals 89.1%
because 11 of 101 pieces could not be delivered directly from stock.
It can be seen that by choosing one service level over the other totally
different values can occur. Thus, there is no overall right decision. It
depends upon circumstances. If it does matter how many pieces of an
order could not be delivered, one should use the β-service, but if it is an all
or nothing evaluation of whether the inventory management is successful,
the α-service is the appropriate performance measure.
2.1 Supply Chain Performance Measurement 11
Inventory Turnover
The inventory turnover η indicates how often the average inventory level is
sold within a given period. Therefore, it focuses on the fixed capital of the
inventory. Additionally, as a dimensionless measure it allows to compare
the inventory level of two different SKUs. It is defined as the ratio of the
sales of a SKU and its average inventory level:
T
yt
t=1
η= . (2.3)
1
T
T It
t=1
Compared with the service measures, one can see that the inventory turnover
does not regard the customer at all. It is a purely inventory focused mea-
sure and is not used to find an optimal inventory policy. In most setups
inventory management needs to fulfill a certain service constraint while
minimizing the total inventory costs. Thus, a high inventory turnover re-
sults from a good inventory policy. The average inventory level in each
period is the mean value of the inventory level at the beginning of the
period (inventory level at the end of the previous period plus deliveries)
and the inventory level at the end of the period. Therefore, the average
inventory levels of the five periods are 20, 10, 7.5, 13, and 14. For the given
example, η equals 7.83 because in total 101 pieces are sold and the overall
average inventory level is 12.9.
12 2 Inventory Management
The relevant costs of an inventory control system are split into three differ-
ent parts. First, the order costs which arise with an order. These are costs
like the handling, transportation or labor costs, as well as the variable costs
of an order, which may vary due to quantity discounts (Axsäter, 2006, p.
44ff). The order costs per unit decrease as the order quantity increases. So
there is a positive impact of high order quantities on order costs. This part
of the inventory costs can be estimated with data provided by internal ac-
counting. Themido et al. (2000) and Everaert et al. (2008) discuss the use
of activity-based costing models to determine the handling, transportation
and order costs. They argue that the use of activity-based costing models
can increase the accuracy of a company’s logistic costs estimation.
The second part of the inventory costs are the holding costs, which occur
when keeping SKUs on stock. The holding costs again consist of different
parts. There is the interest which needs to be paid for the fixed capital and
the opportunity costs of using this fixed capital in a different way. There are
the costs of running the warehouse, and even if they are non-cash expenses,
the risk of spoilage of perishable goods and thievery needs to be regarded
because they increase at higher inventory levels (Axsäter, 2006, p. 44).
Overall the holding costs will rise with the order quantity, thus there is a
2.2 Relevant Costs 13
cov(uM ; ui )
ωi = , (2.4)
var(uM )
where cov(uM ; ui ) denotes the covariance between the rate of return of the
asset and the rate of return of the market. var(uM ) denotes the variance
of the return of the market portfolio. Based on this risk ωi measure, the
expected rate of return can be calculated using the following equation:
ui = uf + ωi · (uM − uf ) , (2.5)
where uf is the return of a risk free asset. Jones and Tuzel (2013) showed
a relationship between the risk measure of the CAPM and the inventory
levels of a company in an empirical study. Therefore, there is empirical
evidence that the estimated ωi influences inventory decisions. The CAPM
is used to estimate the opportunity costs of capital in different industry
sectors in Europe in order to give an indication about the inventory holding
costs. This might not be a very accurate measure, but it will provide a
1 The proposed risk measure is usually denoted as β, but for reasons of consistency ω
will be used.
14 2 Inventory Management
suitable estimate. Table 2.2 lists the results of an empirical analysis using
the CAPM. It is based on the stock returns of 9 833 European companies
in 39 industry sectors between January 2000 and May 2014 (Bloomberg,
2014). The different ω-values were calculated by comparing the returns of
the different sector portfolio, i.e. an equally weighted portfolio containing
all the companies of a sector, and the market portfolio containing all 9 833
shares. The risk-free rate was assumed to be 0.045, which equals the average
return of a German federal bond during this period. In addition to the
expected interest rate, the table also lists the 95% confidence interval of
the expected interest rate, the average gross margin, and the number of
sampled companies of the sector.
The third part of the inventory costs arise with a stock out. They are
called shortage or lost sales costs. To define these costs, it needs to be
distinguished whether, in case of a shortage, the customer is willing to wait
until the product is available again. If so, there are additional costs of
express deliveries or compensation discounts. If the customer is not willing
to wait, the sale is lost and therefore, the company will not earn the gross
margin. In addition, the customer is unsatisfied. This raises the risk that
the customer may switch to a competitor. The costs of an unsatisfied
customer are called loss of goodwill costs and whereas the gross margin
is relatively easy to estimate (see Table 2.2), the estimation of the loss of
goodwill costs is almost impossible (Crone, 2010, p. 39). The risk of a
stock out falls with higher order quantities. Thus, higher order quantities
have a positive impact on the lost sales costs.
After describing the three parts of the inventory costs, it can be seen that
there is a trade-off between high order quantities, which reduce the order
and lost sales costs, and the low order quantities, which cut the holding
costs. Therefore, one goal of inventory management is to find an order
quantity, which balances these different costs.
2.2 Relevant Costs 15
Table 2.2: Expected interest rate and gross margin of European industry sectors.
16 2 Inventory Management
These four inventory policies also include several special cases. For exam-
ple, the news vendor model for highly perishable goods can be formulated
as a base-stock policy (Bouakiz and Sobel, 1992). The intuition behind
those base-stock policies is to order whenever the inventory level is reduced
such that the inventory level is S at the beginning of each period. They are
in fact (s,S,T ) policies, but due to their special properties they are referred
to as (S − 1,S,1) policies.
r,Q,T r,S,T
30 S
Inventory
20
10
0
Orders
32
29
26
5 10 15 20 25 5 10 15 20 25
s,Q,T s,S,T
30 S
Inventory
20
10
s s
0
Orders
32
29
26
5 10 15 20 25 5 10 15 20 25
To state the behavior the four different inventory policies, Figure 2.2 shows
the inventory levels and order sizes over 30 weeks of simulated inventories
using each of these different policies. The rows separate the decision about
when an order is placed whereas the columns seperate a fixed order size
from a flexible one. All four graphs are based on the same demand series
18 2 Inventory Management
and parameters. The order size Q and the order up-to-level S are set to
30 the fixed interval between two orders r is 10, and the reorder point s
is 5. Once an order is placed, it takes 2 weeks until the delivery arrives.
Thus, the lead time L is 2 and the review period T is 1 week for all graphs.
The upper-left graph plots the inventory and order sizes of the (r,Q,T )
policy based on the given parameters. The first order is placed in period
4 and arrives two weeks later in period 6. One can see that all order
sizes are equal, and the time between two consecutive orders is fixed at 10
weeks. The dotted line denotes the inventory position, which equals the
inventory level plus the future deliveries. Therefore, the inventory position
and inventory level are equal if no delivery is in progress. As in Figure 2.1
the gray shaded inventory marks a backlog. For the first policy this is the
case in period 5, 15, 23, 24 and 25.
The second graph shows the results of a (r,S,T ) policy and has the same
structure as the first graph. Additionally, the horizontal dashed line marks
the order-up-to level S. As in the first graph, the orders are equidistant,
but in this graph they differ in size. The order size is selected in the way
that the order will raise the inventory position to S, in other words the
order size is equal to S − It . Thus, the order-up-to level is an upper bound
of the inventory position. The inventory level will not reach the order-up-to
level in most cases, even if the inventory position does, due to the demand
during the lead time L.
The third graph shows the results of a (s,Q,T ) policy. In this case an order
of Q pieces is placed whenever the inventory position drops below s (dashed
line). The inventory position is used for the order rule because it gives clear
instructions, unlike the inventory level. Consider an order policy based on
the inventory level. An order would be placed not only in week 3, but also
in week 4, because the inventory level is still below s since the delivery has
not arrived yet. In contrast, a rule based on the inventory position will
not lead to further orders. Only one order is placed in week 4, because the
2.3 Inventory Policies 19
The last graph shows the results of a simulated (s,S,T ) policy. The in-
ventory position fluctuates between the reorder level s and the order-up-to
level S. Similar to the third graph, the first order is placed in week 3,
whereas the second and third orders are placed in period 13 and 20. Back-
logs appear in period 14 and 21. This inventory policy has the highest
adaptability, and Sani and Kingsman (1997) show that in case of inter-
mittent demand series, the (s,S,T ) policy suits best. Therefore, a (s,S,T )
policy is described and used in the following.
20 2 Inventory Management
The challenges which arise from an uncertain demand are based on the com-
bination of two circumstances, the uncertain demand, and the positive lead
time. For example, if there is no lead time (L = 0) one would place an order
whenever the inventory level falls to zero (s = 0) no matter how volatile
the demand is because it would be delivered immediately. If the demand is
certain and the lead time is positive, one would place the order such that
the remaining stock lasts until the next order arrives. As this generally
also holds for the case of a positive lead time and an uncertain demand, a
new problem arises. It could be the case that the reorder point s, i.e. the
amount that should last until the new order arrives, is too low. Thus, the
demand cannot be satisfied from stock, and will be backlogged. This leads
to shortage costs and unsatisfied customers. Therefore, an inventory policy
based on stochastic demands needs to regard those uncertainties and the
resulting costs. This can be done by finding a set of inventory variables,
e.g. the reorder point s and the order-up-to level S, which minimizes the
total inventory costs as the sum of order, holding, and shortage costs. But,
as mentioned above, it is hard to estimate the loss of goodwill costs which
provide the main part of the shortage costs (Crone, 2010, p. 39). To avoid
this issue, the selection of s and S can be based on minimizing the sum
of the holding and order costs while satisfying a certain service constraint,
e.g. find s,S such that an α-service level of 95% is achieved at minimal
cost. This method avoids the need to determine the shortage costs because
they are implicitly assumed by selecting a service target. Those service
constrained inventory policies will be used in the following.
As described above by using a (s,S,T ) policy the inventory position will vary
between the two bounds s and S. There are some approaches to determine
S based on the demand series directly (e.g., see Teunter, Syntetos, and
2.3 Inventory Policies 21
Babai (2010)), but in most cases S results from selecting a reorder point
s and the gap between s and S, denoted as D. This position gap D is
selected such that the sum of the order and inventory costs are minimized.
Thus, the remainder of this section describes the economic order quantity
model to determine the gap D.
The widest used inventory model is the economic order quantity model de-
veloped in F. W. Harris (1990).2 This model can be denoted as a (r,Q,0)
policy because the order interval and quantity are constant, and the in-
ventory is known at every point in time. It determines the cost optimal
position gap D∗ based on the assumption that the lead time is zero and
that the underlying demand series is a continuous-time continuous-space
time series with a constant demand rate. The demand needs to be fulfilled
immediately, i.e. shortages are not allowed. Based on these assumptions,
the optimal solution can be derived in a straightforward manner. As short-
ages are prohibited and the lead time is zero, a cost optimal order is placed
everytime the invetory level reaches 0. Therefore, the total costs C(D) are
determined by the order and holding costs:
μy D
C(D) = ·K + ·h , (2.6)
D 2
order costs holding costs
2 The original publication by Harris dates back to 1913 while this citation refers to the
digital reprint in 1990.
22 2 Inventory Management
derivative.
μy D ∗ 2 · μy · K
minimize C(D) = ·K + ·h ⇒ D = . (2.7)
D D 2 h
The underlying assumptions of the EOQ are very strict and will not hold
in many practical setups. Therefore, the literature provides extensions to
the EOQ in order to reduce the strictness of the assumptions. Axsäter
(2006, p. 55 ff) considers the EOQ in case of finite production rates and
discounts. Grubbström and Erdem (1999) derive an adapted version of the
EOQ with backlogging and Weiss (1982) and Goh (1994) regard nonlinear
holding costs. There is also a wide range of literature dealing with imperfect
SKU quality (see Khan et al. (2011) for a review). A historical review and
several other extensions of the EOQ are given in Choi (2013).
Haneveld and Teunter (1998) show that in case of slow moving demand, an
inventory policy based on maximizing the discounted cash flows instead of
minimizing the inventory costs leads to better results. This addresses the
main drawback of the EOQ model. The strict assumption of a certain and
fixed demand rate. While this leads to the straightforward derivation of
the optimal order quantity D∗ , it does not reflect the majority of practical
settings in which the future demand is uncertain and variable.
Nevertheless, the original EOQ model is still frequently used due to its
easy implementation and robustness against violations of the assumptions
(Drake and Marley, 2014). Therefore, and for reasons of comparability, the
EOQ will be used to determine the inventory gap D even if there may be
potential issues.
other words not going out of stock. In general the literature provides the
following rule to determine the reorder point for a given α-service constraint
(Schneider, 1978):
s
fltd (x) dx = α . (2.8)
−∞
s
pltd (i) ≥ α . (2.9)
i=0
This rule has the same interpretation as (2.8) and it is theoretically much
closer to an observed demand series, but it has the drawback that it does
not have an unique solution for s. The reorder point is the smallest s which
satisfies condition (2.9). This is equal to the definition of the Value-at-
Risk, a frequently used risk measure for financial assets in portfolio theory.
Therefore, the determination of s for a given α-service level can also be
interpreted by means of portfolio theory. Figure 2.3 shows the quantile
function of the lead time demand. The dashed lines indicate an α-service
level of 95% and the resulting s.
α service constraint
30
lead time demand
20
s
10
0
0.00 0.25 0.50 0.75 α 1.00
cumulative prob.
the case of intermittent demand series this assumption could lead to poor
results. Intermittent demand series have a low mean value and a relatively
high variance. Therefore, a normal distribution based on those values will
have a considerable positive density in the negative range. To avoid these
problems, the literature provides inventory policies which are based on the
gamma distribution (e.g., see Dunsmuir and Snyder (1989) and Moors and
Strijbosch (2002)). This distribution is only defined for positive values and
is therefore a suitable supplement to the normal distribution. In addition,
the gamma distribution is also completely defined by the first two central
moments and is convolution invariant. Thus, in the following the reorder
points are approximated using the normal distribution and additionally the
gamma distribution.
2.3 Inventory Policies 25
where μltd is the expectation, μ2ltd is the second moment and σltd is the
standard deviation of the lead time demand. erfc(x) is the complemen-
tary error function (Abramowitz and Stegun, 1972, p. 297). If a gamma
distribution is assumed, s can be found as the root of the following approx-
imation
μltd · Γ(p + 1,b · s) s · Γ(p,b · s) μ2ltd !
f (s) = − − (1 − α) D + =0 ,
Γ(p + 1) Γ(p) 2 · μltd
(2.12)
∞
(x − s)fltd (x) dx = (1 − β) · D . (2.13)
s
inequation (2.14):
∞
(i − s)pltd (i) ≤ (1 − β) · D . (2.14)
i=s
β service constraint
0.30
exp. lost sales / order size
0.25
0.20
0.15
0.10
0.05
0.00
0 10 20 30
s
q2
(β − 1)(2Dμltd + μ2ltd ) 1 2 q e− 2 q !
f (q) = 2 + q + 1 · erfc √ + √ =0 ,
σltd 2 2 2π
(2.15)
s = μltd + q · σltd . (2.16)
μY
ltd = L ·
μ+
πltd
, (2.19)
28 2 Inventory Management
All the described inventory policies rely on the knowledge about future de-
mand. The EOQ assumes this future demand to be certain with a constant
demand rate. In contrast, the definition of the variables of the described
(s,S,T ) policies rely on the knowledge of the future lead time demand distri-
bution. If a continuous lead time demand distribution is assumed, informa-
tion about the first two moments of the lead time demand will be needed.
This chapter deals with methods utilized to estimate the expectation and
variance of the future demand for intermittent demand series.
From a statistical point of view every ordering event of a given SKU pro-
duces mainly two kinds of information: The amount and the timestamp of
the order which together form the demand time series. Due to the slow
stock rotation of intermittent SKUs, the special property of these time se-
ries is the high share of periods with a non-positive demand (yt = 0) even if
the degree of aggregation is high like weeks or month (Syntetos, Babai, et
al., 2011, p. 34). Thus, the methods described in this chapter are designed
to take into account the features of intermittent time series.
Section 3.1 provides a short introduction into time series analysis and the
notation used. After that, Section 3.2 describes the most common fore-
casting models for intermittent demand, which are based on the work of
Croston (1972). But as mentioned above, determining the reorder level is
based on the knowledge of the probability mass function (PMF) of the fu-
ture demand. Therefore, Section 3.3 introduces integer-valued autoregres-
sive moving average processes, which can be used to estimate the complete
future PMF of the demand during lead time.
Yt = εt ∀t , (3.1)
where the random variable εt may follow any distribution, but in most
cases it is assumed that εt follows a normal distribution, which makes the
process called Gaussian white noise. Thus, if εt ∼ N (μ,σ 2 ), the expectation
and variance of the process is equal for all periods t. This property of a
DGP is known as mean and variance stationarity. If the DGP regards linear
combinations of the preceding random variables, the process is called an
autoregressive process. Equation (3.2) denotes an AR(1) process as the
random variable Yt is a linear combination of one past random variable
Yt−1 and the error term εt . Thus, an AR(2) process would consider the
last two random variables, and a general AR(p) process would regard the
last p random variables.
Yt = φ · Yt−1 + εt . (3.2)
linear combination of the past and current error terms. The MA process is
mean and variance stationary, regardless of the value of the parameters ψ.
Yt = εt + ψ · εt−1 . (3.3)
γ(h)
ρ(h) = . (3.5)
γ(0)
32 3 Demand Analysis and Forecasting
Figure 3.1 shows the theoretical ACF and PACF of an AR(2) and MA(2)
process. The parameters of the two processes are φ = {0.3,0.2} and ψ =
{0.3,0.2}. It can be seen that the ACF of an AR process decreases expo-
nentially and has a limit of 0. In contrast, the PACF of an AR process
breaks off after the order of the process. This is also the case if the ACF
of an MA process is considered. It breaks off after the order of the process,
whereas the PACF of a MA-process has a more complex structure. The
absolute value of the PACF of a MA process also decreases exponentially
and has a limit of 0.
Due to the properties of the ACF and PACF, i.e. the respective break off
after the process order, they can be used to identify the processes. For
example if the PACF of a process breaks off after lag 1 and the ACF
exponentially decreases, the underlying DGP is an AR(1) process.
After describing the fundamentals of time series analysis, the next two
sections deal with two different approaches to model intermittent demand
series. First, Section 3.2 introduces the class of methods based on Croston
(1972) and Section 3.3 presents the integer-valued autoregressive processes.
3.2 Croston-Type Models 33
ACF PACF
0.3
0.2
AR
0.1
0.0
-0.1
0.3
0.2
MA
0.1
0.0
-0.1
1 3 5 7 9 1 3 5 7 9
lag
Figure 3.1: Theoretical ACF and PACF of an AR(2) and an MA(2) process
Yt = Xt · Yt+ ∀t , (3.7)
Xt ∼ Ber(πY ) +
, (3.8)
2
Yt+ ∼ N (μ+
Y
,σY+ ) , (3.9)
34 3 Demand Analysis and Forecasting
Based on these definitions, the next steps in Croston (1972) are straight
forward. Due to the independence of Yt+ and Xt the expectation of Yt can
3.2 Croston-Type Models 35
12.5
10.0
7.5
Yt
5.0
2.5
0.0
10 20 30 40 50
t
be written as:
1 1
δ= ⇐⇒ πY+ = , (3.11)
πY+ δ
1 + μ+
E(Yt ) = πY+ · μ+ = ·μ = Y . (3.12)
Y δ Y δ
ŷt+ = α · yt + (1 − α) · ŷt−1
+
, (3.13)
dˆt = α · dt + (1 − α) · dˆt−1 , (3.14)
36 3 Demand Analysis and Forecasting
C ŷt+
ŷt+h = , (3.15)
dˆt
2 2
2 +2
(1 − δ) · μ+ + σY+
V C
(ŷt+h ) = α σY + α(1 − α) δ
2 Y
, (3.16)
2−α
Based on the fact that Croston uses simple exponential smoothing to calcu-
late the components ŷt+ and dˆt , the forecasting procedure is similar to the
method of exponential smoothing. The first step of the forecast procedure
is determining the start values. After that Equations (3.13) and (3.14) are
used to fit the parameters and in the last step Equation (3.15) is used to
calculate the forecast.
The forecast is based on the recursive equations given in (3.13) and (3.14).
A recursive definition always leads to the question of how to set the starting
values in case t = 1. The literature provides several different approaches
to address this problem, but in contrast to other approaches the version
provided in Willemain et al. (1994, p. 535f) is based on the values of the
ŷ0+ = yf , (3.17)
dˆ0 = f . (3.18)
The constant f defines the index of the first period with a positive demand.
Therefore, ŷ + is equal to the first positive demand, and dˆ0 is set to the
0
index of this period.
After defining the starting values, one needs to select a proper smoothing
parameter α. Generally there are three ways of doing so. First, a value can
be chosen externally without regarding the data. The literature suggests
values between 0.1 and 0.3 (see Croston (1972) or Gardner Jr. (1985) for
example). This is clearly the most convenient way to determine α, but
Gardner Jr. (2006, p. 651) argue that there is no reason to choose exoge-
nous smoothing parameters due to the suitable search algorithms. There-
fore, the second option is to select α via numerical optimization, such that
the resulting α minimizes the forecasting error. For example, set α to the
value which minimizes the mean squared error of the one-step-ahead fore-
cast. These error measures are considered in Section 3.4. The third way
of finding α is to estimate it by means of statistical inference. While there
is a progress in finding stochastic models underlying adhoc methods like
exponential smoothing, this is not the case for the Croston method. For
example, Hyndman, Koehler, et al. (2008) have developed a state space
formulation of many exponential smoothing methods, which leads to tools
of statistical inference like estimating parameters and forecasting intervals.
But Shenstone and Hyndman (2005) argued that there is no consistent
stochastic model underlying the Croston procedure. Therefore, determin-
ing α by statistical estimation is not considered furthermore and numerical
optimization is used hereafter.
By using these starting values and the smoothing parameter, the model
is fitted along the time series. Within this procedure two different cases
38 3 Demand Analysis and Forecasting
are distinguished. If the demand in period t is positive, ŷt+ and dˆt are
calculated using equations (3.13) and (3.14) whereas dt is set to 1. If yt is
zero, the parameters will not change and will be carried over into the next
period. The variable dt , which measuring the number of periods between
two positive demands, is incremented by 1.
ŷt+ = ŷt−1
+
, (3.19)
dˆt = dˆt−1 , (3.20)
dt = dt−1 + 1 . (3.21)
Figure 3.3 illustrates this process of parameter fitting. The upper part
shows the simulated time series of Figure 3.2 together with the result
of (3.13) and (3.15). The lower part shows the variable dt and the re-
sult of (3.14). It can be seen that dt is incremented by 1 in each period
with a zero demand and is set down to 1 if yt is positive. The dotted line in
the lower part shows the estimation of dˆt , which is only updated in periods
with a positive demand. The dotted line in the upper part of the graph
shows the estimation of ŷt+ , which is equal to the exponential smoothing of
yt while excluding all periods with zero demand. The dashed line shows the
fitting of the Croston procedure. It is also only updated when the demand
is positive. Despite the fact that the Croston method is widely accepted
as the default forecasting procedure for intermittent demand (Babai, Syn-
tetos, and Teunter, 2014), there are some issues with this method.4 For
example, there are problems with the model specification. Croston (1972)
ignores the fact that the number of sales is naturally discrete and assumes
Yt+ to be normal distributed. Additionally, updating the forecast only in
periods with a positive demand leads to long periods without updating the
parameters if the demand is highly intermittent. Separating the demand
into two independent random variables Yt+ and Xt , i.e. assuming that the
level of demand is independent from its occurrence, is a very strict assump-
4A more detailed overview over the issues of the Croston method can be found in
Gardner Jr. (2006, p. 655f).
3.2 Croston-Type Models 39
12.5
10.0
7.5
Yt
5.0
2.5
0.0
10.0
dt
5.0
0.0
10 20 30 40
t
Figure 3.3: Parameter fitting of the Croston procedure
C
tion. Syntetos and Boylan (2001) show that the estimator ŷt+h is positively
1
biased. This is due to the fact that E(X) = E X (Teunter, Syntetos, and
1
Babai, 2011). Therefore, they suggest that the Croston procedure should
not be used.
To correct the bias of the Croston estimator, Syntetos and Boylan (2005)
S
provide a new estimator denoted as ŷt+h in a later work:5
α ŷt+
S
ŷt+h = 1− · . (3.22)
2 dˆt
S
Compared with the original Croston estimator, ŷt+h is weighted with the
factor 1 − 2 where α is the smoothing parameter used in (3.13) and (3.14).
α
Since α is defined between 0 and 1, the correction takes values between 0.5
(α = 1) and 1 (α = 0) and therefore reduces the forecast. The authors do
not change the structure of the Croston procedure. Thus, the initialization,
the calculation of α, and the parameter fitting remain the same.
5 Syntetos and Boylan (2001) already provide an unbiased estimator but the literature
makes no mention about this version, therefore only the estimator given in Syntetos
and Boylan (2005) is used hereafter.
40 3 Demand Analysis and Forecasting
ŷt+ = α · yt + (1 − α) · ŷt−1
+
, (3.25)
π̂t+ = β · xt + (1 − β) · π̂t−1
+
, (3.26)
0 if yt = 0
xt = , (3.27)
1 else
3.2 Croston-Type Models 41
In all cases the forecast is calculated as the product of the smoothed prob-
ability of a positive demand π̂t+ and the smoothed level of the positive
demands ŷt+ :
T
ŷt+h = π̂t+ · ŷt+ . (3.28)
In addition the authors provide an adapted calculation rule for the forecast-
ing variance, which accounts for the two different smoothing parameters.
2 2 2 2
T
απY+ σY+ βπ + (1 − πY+ )μ+ αβπY+ (1 − πY+ )σY+
V (ŷt+h ) = + Y Y
+ .
2−α 2−β (2 − α)(2 − β)
(3.29)
Eaves and Kingsman (2004) compare the Croston method, the adapted
version provided in Syntetos and Boylan (2005), exponential smoothing,
and a moving average approach. The authors compare the methods using
different forecasting performance measures and the resulting stock levels.
42 3 Demand Analysis and Forecasting
Although the results could not confirm the overall performance increase of
Croston compared with exponential smoothing, but the authors state that
the adaption of Syntetos and Boylan performs best.
Teunter and Duncan (2009) focus on forecast performance measures and the
achieved service levels. They could not confirm the results of the first two
empirical studies in case of the forecast performance measures. However
they showe that using Croston-type methods can improve the resulting
service levels.
Babai, Syntetos, and Teunter (2014) is the first comparative study which
also includes the Croston adaption developed in Teunter, Syntetos, and
Babai (2011). The authors use two different industry datasets. In one
dataset the Croston procedure performed better than exponential smooth-
ing while in the other dataset the opposite occurred. In both cases the
adaption of Syntetos and Boylan and Teunter, Syntetos, and Babai (2011)
lead to an increase in forecast performance compared with the Croston
procedure.
This section introduces the integer-valued version of the widely used Box-
Jenkins autoregressive moving average (ARMA) models. The restriction to
a discrete state space while retaining several of the statistic properties of
classical ARMA models is achieved through the introduction of the bino-
mial thinning operator. The usage of integer-valued autoregressive moving
average processes (INARMA) has several advantages compared with the
ad-hoc methods described before. First, all forecasting models presented
in Section 3.2 only estimate the first two central moments of the demand
series and lack of a consistent theoretical basis. In addition, the forecasts
based on INARMA processes are coherent, i.e. they satisfy all constrains
of the demand time series, which is the foundation of a suitable time series
model (Chatfield, 2000, p. 81).
The idea of INARMA processes is that the demand in period t results from
two mechanisms. First, the current demand depends on the sales of the
last periods, i.e. how much demand of the past periods ’survives’. Second,
the current demand depends on the outcome of an innovation process. This
idea has been first introduced in Al-Osh and Alzaid (1987) by defining the
first order integer-valued autoregressive process (INAR(1)) as follows:
Yt = φ ◦ Yt−1 + εt . (3.30)
current demand lingering demand new demand
The demand in period t (Yt ) is the sum of the lingering demand of the
last period φ ◦ Yt−1 and the new demand εt . The ’◦’ denotes the binomial
thinning operator developed in Steutel and Harn (1979). It is defined as
the sum of Yt−1 many independent and indentically distributed Bernoulli
random variables with P (Bi = 1) = φ:
X
φ◦X = Bi , (3.31)
i=1
Bi ∼ Ber(φ) . (3.32)
4
Demand
3 φ ◦ Yt−1
Yt
εt
2
0
5 10 15
t
Figure 3.4: Simulated INAR(1) process
According to Alzaid and Al-Osh (1990), Jung and Tremayne (2006), and
Bu and McCabe (2008) the INAR(1) process can be generalized considering
more timelags. Equation (3.33) defines a general INAR(p) process with p
different timelags.
where the general intuition remains the same, but the demand Yt now
depends on εt and the demands of the last p periods.
(3.35)
p
q
INARMA(p,q): Yt = φi ◦ Yt−i + εt + ψi ◦ εt−i . (3.36)
i=1 i=1
T 2
Q(φ̂,λ̂) = yt − (φ̂1 · yt−1 + φ̂2 · yt−2 + ... + φ̂p · yt−p + λ̂) ,
t=p+1
(3.37)
2
T
p
Q(φ̂,λ̂) = yt − φ̂i · yt−i − λ̂ , (3.38)
t=p+1 i=1
48 3 Demand Analysis and Forecasting
where φ̂ is the vector of the estimators for the different INAR lags. λ̂
denotes the estimator for the expectation of the Poisson marginal. There-
fore, the estimators are chosen to minimize the overall quadratic difference
between the expected value of yt and the observation. This minimization
could either be done by setting the gradient to zero, or due to the convexity
of Q(φ̂,λ̂) the minimum can also be obtained through numerical optimiza-
tion using the Nelder-Mead Algorithm (Nelder and Mead, 1965). Du and Li
(1991) show that the conditional least squares estimator is asymptotically
normal and strongly consistent.
The most recent approach for estimating the parameters of a general IN-
ARMA(p,q) has been developed in Neal and Subba Rao (2007). It is a
Markov Chain Monte Carlo (MCMC) approach which estimates all the
parameters simultaneously. This approach is briefly described below.
First the estimators φ̂1 ,...,φ̂p ,ψ̂1 ,...,ψ̂q and λ̂ are drawn from random dis-
tributions. One after another all φ̂’s and ψ̂’s are updated following a beta
distribution whereas λ̂ is drawn from a gamma distibution.
3.3 Integer-Valued Autoregressive Moving Average Processes 49
After updating the estimates, they are used to guess which Bernoulli out-
comes could have led to the observed time series. These guesses are then
used in the next iteration step to update the estimates.
The stationary distribution of the Markov chain, i.e. the distribution of the
estimates, is determined by storing the estimates over several iterations.
However, the average of the stored estimates is used as the estimators of
the p + q parameters and λ.
min(x,yt )
yt
p̂(Yt+h = x|yt ) = (φ̂h )i (1 − φ̂h )yt −i
i
i=0
x−i
1 1 − φ̂h 1 − φ̂h
· exp −λ̂ · λ̂ . (3.39)
(x − i)! 1 − φ̂ 1 − φ̂
...
min(x−(i1 +...+ip−1 ),yt−p )
yt−p ip
· φ̂p (1 − φ̂p )yt−p −sp
ip
ip =0
2 2 2 2
1 1 1 1
0 0 0 0
because the last observation (y30 ) is above the unconditional mean of the
demand series. An important fact is that the PMFs are not symmetric and
that each PMF depends on its predecessor, as described in this section.
P (yt+h )
10
0.12
yt
0.08
5
0.04
0
1 10 20 30 40
t
Neal and Subba Rao (2007) also propose a method to determine the fu-
ture PMF of a mixed INARMA process. They use the MCMC approach
described in Section 3.3.2, but instead of using the past observations to
guess the Bernoulli outcomes of the process, they use the sampled values
of the MCMC approach itself. This has the advantage that it is possible to
calculate the future PMFs of general INARMA(p,q) processes, but there is
no report about a practical application of this approach.
As described in Section 2.3.3 information about the lead time demand, i.e.
the PMF of the demand during the lead time p̂ltd (x) is needed in order to
optimize the reorder point s.
h
p̂ltd (x) = P ( Yt+i = x|yt ,yt−1 ,...,yt−p+1 ). (3.42)
i=1
In most cases this PMF is obtained by the convolution of the future PMFs
while assuming the independence of Yt ,Yt+1 ,...,Yt+h (Nahmias, 1979, p.
3.3 Integer-Valued Autoregressive Moving Average Processes 55
h
P( Yt+i =x|yt ,...) =
i=1
1 x−(j
x x−j 1 +j2 )
x−(j1 +j2 +...)
...
j1 =0 j2 =0 j3 =0 jh−1 =0
The right-hand side of this equation is the sum of the probabilities of all
intersections which equal x. If x were 0, for example, there would be just
one summand, i.e. the probability of all future values (Yt ,...,Yt+h ) would
be zero. If x is 1, there are h many summands, i.e. the probability of
one future observation equals 1, and all others are zero. The formulation
given in (3.43) may help to calculate the p̂ltd (x) of an INAR(1) process,
but finding a formulation for the intersection probabilities of an INAR(p)
or even an INARMA(p,q) will be hard if not impossible. Therefore, in the
following a more intuitive way using graph representation will be presented
to calculate those intersection probabilities. It is based on the same idea
of defining the process as a finite space Markov chain described above.
The Markov chain will be defined as a directed acylic graph, where the
different states, i.e. the vertices, represent the values of Yt ,Yt+1 ,...,Yt+h
and the edges represent switching probabilities from one state to next.
Additionally, an auxiliary vertex E with edges connecting every state of
the last layer (t + h) to it has been added to the graph.
three ((G + 1)-many) edges leading to the next layer of the graph marked
with (t + 1). The next layers (t + 2,t + 3,...) will have (G + 1)2 reachable
vertices, where every vertex except for those in the (t+2) layer are reachable
from G + 1 preceding vertices. All vertices of the (t + h) layer are connected
to the auxiliary end vertex E. All (G + 1)h -many paths from the starting
vertex (1,0) to the end vertex E represent the plausible outcomes of the sum
of the future random variables Yt+1 ,...,Yt+h . By weighting the edges with
the switching probability and the vertices with the current value of Yt , the
length of the path indicates the probability of that path, while the visited
vertices provide information about the resulting value of hi=1 Yt+i of that
path, i.e. the sum of the vertex weights (bold number). The edges which
connect the last layer (t + h) to the auxiliary end vertex E are weighted
with 1. Let P be the set of all paths from (1,0) to E and let Px denote the
subset of this paths where the sum of the weights of the visited vertices
equals x. Each path p is defined by the used edges (e1 ,e2 ,...,eh+1 ). Thus,
the probability mass function of the demand during the lead time can be
3.3 Integer-Valued Autoregressive Moving Average Processes 57
defined as:
h+1
p̂ltd (x) = f (ei ), (3.44)
pPx i=1
where f (e1 ) is the probability of switching from the first to the second
vertex in this path. This probability is calculated using Equation (3.41).
In most cases the number of states in a layer is much higher than the
number of layers. The set of all possible paths should be determined using
depth-first search. An advantage of this formulation is that it is based on
the methods and terms which are used in operations research (e.g., see Sun
and Queyranne (2002)).
where g(ei ) = ln f (ei ). Using this definition the summation of the edge
weights is meaningful. The only drawback of using logarithmic probabilities
as edge weights is, that this leads to negative edge weights, only a subset
of graph algorithms is suitable for graphs with negative edge weights.
The calculation of p̂ltd (x) relies on the evaluation of all possible paths
between the starting vertex (0,1) and the auxiliary end vertex E. As men-
tioned above, the cardinality of this set P rises polynomially with the num-
ber of states and exponentially with the number of layers (|P | = (G + 1)h ).
Therefore, the calculation of p̂ltd (x) is complex especially if the lead time
58 3 Demand Analysis and Forecasting
is high. Due to the fact that the aim of this procedure is to calculate the
future PMF and that the majority of paths will have very low probabili-
ties, much computational effort is misspent in paths with low probabilities.
Hence, the next step is to reduce the set of all possible paths to the most
plausible ones.
Beside the estimate of the future probability mass functions and their lead
time aggregation, point forecasts may also prove useful. This section pro-
vides two different ways to calculate those point forecasts. The first ap-
proach is to predict the future expectation. The interpretation of the re-
sults is very close to the point forecasts calculated using the Croston-type
3.3 Integer-Valued Autoregressive Moving Average Processes 59
method. For a given PMF of the future demands the calculation of ŷt+h is
straightforward:
∞
ŷt+h = i · P̂ (Yt+h = i) , (3.46)
i=0
where P̂ (Yt+h = i) can be calculated using (3.41). Due to the Poisson in-
novations of the INAR process this sum has theoretically infinitely many
summands, but as mentioned above most of the summands will be rela-
tively small. Thus, one can replace the upper limit of the sum with G
in order to simplify the calculations (see Section 3.3.3). The drawback of
this approach is that it will produce forecast values which do not satisfy
the constraints of the underlying model, i.e. the values of ŷt+h calculated
using Equation (3.46) are not integer values. In order to avoid this issue,
the literature provides techniques to produce coherent forecasts (e.g., see
Freeland and McCabe (2004) and Jung and Tremayne (2006)). Therefore,
the second approach described in this section is a coherent approach based
on the median.
The specification of ŷt+h based on the median is also based on the PMF of
Yt+h :
y
ŷt+h = inf y| P̂ (Yt+h = i) ≥ 0.5 . (3.47)
i=0
The future demand estimate ŷt+h is defined as the infimum, i.e. the highest
lower bound for which the cumulative probabilities of Yt+h exceeds 0.5.
This specification will always lead to integer-valued forecasts.
The MAE assumes a linear loss function and thus, every deviation is
weighted equally. In contrast, due to the squaring of ε̃t the MSE weights
larger deviations between the forecast and the observation higher than
smaller ones. This also implies that the MSE is not on same scale as
the underlying time series. Therefore, the root of the MSE, the RMSE,
is reported in most cases. Using the median to aggregate the error terms
instead of the mean leads to an outlier-robust measure.
Scale-dependent performance measures are suited for low count time series,
and they allow the comparison of different forecast methods for the same
time series. However, due to their scale dependency a direct comparison of
the forecast performance of different time series is impossible.
To avoid this problem Hyndman and Koehler (2006) propose using scaled
performance measures. They differ from scale-dependent performance mea-
sures by weighting the error term with the MAE of the in-sample naive
forecast as follows:
ε̃t
qt = , (3.53)
T
1
T −1 |yt − yt−1 |
t=2
where qt is the scaled error. The future estimates of the naive method are
equal to the current value (ŷt = yt−1 ). Thus, the MAE of this method is
reduced to the sum of the absolute first differences of this time series as
shown in the denominator of (3.53). Analogously these scaled errors can
62 3 Demand Analysis and Forecasting
This chapter provides methods which give information about future de-
mand. This information can be used to determine the reorder point s. The
Croston-type models described in Section 3.2 still need additional assump-
tions about the distribution of the demand during the lead time. In con-
trast, the proposed INARMA processes enable the supply chain manager
to derive the reorder point directly without any additional assumptions.
Therefore, using the PMF forecasts of INARMA processes in order to find
the optimal inventory policy is a consistent approach, and it does not have
any theoretical breaks.
4 Demand Classification
the most lucrative SKUs in the A-cluster and the least in the C-cluster
(Gudehus, 2005, p. 133). This is achieved by sorting and cumulating the
share of SKU revenue. Along this cumulative share the SKUs are classified
for given thresholds, which usually are 0.80 and 0.95 (Gudehus, 2005, p.
134). This means that the most lucrative SKUs, all of which have a share
of revenue of 80% are A-SKUs the next 15% will build the B-cluster and
the last 5% are C-SKUs. This procedure can be used for all positively
valued criteria. Thus, in order to define this procedure formally, let C be
the ordered vector containing the criteria of U -many SKUs. It holds that
Ci ≥ Cj ∀i < j. The share of Ci in the total of the criteria is defined as:
Ci
C̃i = . (4.1)
I
Ci
i=1
Figure 4.1 shows the cumulative sum of the revenue of the data described in
Section 5.1. This plot is called a Pareto chart, and it tracks the cumulative
revenue against the share of the number of SKUs. All three clusters contain
nearly the same share of SKUs. Therefore, about 33% of the SKUs earn
80% of the revenue, the next third earns about 15%, and the last third of
the SKUs generates 5% of the revenue.
0.75
0.50
A B C
0.25
0.00
0.25 0.50 0.75
share of SKUs
After convergence, the last assignment is the solution of the ABC analysis.
The thresholds can be obtained as the highest values of the criteria of the
A and B cluster.
HIL
AB Z
C XY
As mentioned above, all forecast methods are only suitable for specific types
of demand patterns, i.e. if the wrong method is chosen, the forecast quality
will be poor. This fact is utilized by the classification scheme described in
this section. If a forecast method is suitable for a specific type of demand
pattern, it will produce small forecasting errors whereas a non-suitable
method will produce high error measures. Therefore, if the forecasting er-
rors of a certain SKU are poor in case of Exponential Smoothing and are
better when using the Croston method, this SKU might have an intermit-
tent demand pattern. Syntetos, Boylan, and Croston (2005) and Boylan,
Syntetos, and Karakostas (2008) propose a classification scheme based on
this idea. They distinguish between four different demand patterns: inter-
mittent, lumpy, erratic, and smooth and use two different dimensions, the
variation of the positive demands, and the probability of positive demands
as criteria to seperate the demand patterns. This probability of a positive,
i.e. non-zero demand, is denoted as πY+ and is defined as:
Due to the fact that a forecast is usually more difficult for time series with
a higher variation. The variation of positive demands is regularly used as a
measure for the predictability of the demand pattern. Therefore, it is the
criterion in most XYZ analysis setups.
lumpy erratic
CV 2
intermittent smooth
πY+
Beside defining the thresholds, this approach is generally intuitive and pro-
vides a comprehensive overview of the SKUs set structure. Thus, this
classification scheme is used in the remainder to state the different prop-
erties of the SKUs and to determine in which region they will be found.
Figure 4.4 links forecast-based classification to ABC and HIL analysis de-
scribed in Section 4.1. They show the SKU classification scheme of a Ger-
man wholesaler.9 In most cases the SKUs will be irregularly distributed
9 The used dataset will be described in section 5.1.
4.2 Forecast-Based Classification 69
A B C H I L
5 5
4 4
3 3
CV 2
CV 2
2 2
1 1
0 0
0.25 0.50 0.75 1.00 0.25 0.50 0.75 1.00
πY+ πY+
Figure 4.4: Distribution of the ABC and HIL clusters
Consider a MCIC setup with J-many criteria of U -many SKUs and let
cij be the j-th criteria of the i-th SKU. The first step is to transform the
different criteria into a 0 − 1 scale by using Equation (4.4) and (4.5). The
structure of both equations is the same, but (4.5) switches the direction
of the relationship between the input criterion and the final index. Thus,
Formula (4.4) is used in case a higher value of the criterion should lead to
a higher value of the resulting index whereas if Equation (4.4) is used, a
higher value of the criterion leads to a lower value of the resulting index.
where the • notation in c•j denotes a vector containing the j-th criterion
of all SKUs. min() refers to the smallest and max() refers to the largest
value of the vector. Therefore, by using Equations (4.4) and (4.5), the
lowest value of c̃•j is 0, and the highest is 1.
4.3 Multi-Criteria Inventory Classification 71
In the next step the different values of c̃i• are aggregated. As mentioned
above, the advantage of this approach is that the aggregation weights do
not have to be selected in advance. Only the ranking of the criteria must
be specified, i.e. c̃•1 is the most important criterion, c̃•2 is the second most
important, and so on. The weight of a certain criterion is calculated based
on its respective rank. The intuition behind this step is to build the index
Ci based on all measures c̃i• regarding their rank, i.e. if the value of the
most important criterion c̃i1 is higher than all other c̃ij , it should have the
highest weight. If c̃i2 has the highest value, Ci should be a weighted sum
of c̃i1 and c̃i2 . Ng (2007) model this idea as the linear program defined in
the Formulas (4.6) to (4.9).
J
maximize Ci = wij · c̃ij (4.6)
j=1
subject to:
J
wij = 1 (4.7)
j=1
The Objective (4.6) is the maximization of the weighted sum of the cri-
teria of a given SKU by choosing the weights wij while considering three
constraints. Equation (4.7) restricts the sum of all weights to 1. Con-
straint (4.9) is a non-negativity constraint and in addition to Constraint (4.7),
both require Ci to be a weighted arithmetic mean of c̃ij . The rank of the
different criteria is regarded in Constraint (4.8), which ensures that the
weight of the j-th criterion is always greater or equal than the (j + 1)-th
criterion. Without this constraint, the solution would be trivial as the max-
imal Ci is always yielded from weighting the highest c̃ij with 1. Instead
Constraint (4.8) leads to a weighting scheme that equally weights all crite-
72 4 Demand Classification
ria between the most important criteria and the criteria with the highest
value. Table 4.1 lists the different weighting schemes in case of J = 3.
There are three possible weightings schemes if J = 3. Either ci1 , ci2 or ci3
could have the highest value. Thus, if ci1 is the maximum of ci• , wi1 will
be 1, and all other weights will be 0. If ci2 is the maximum of ci• , wi1 and
wi2 will be 0.5, and wi3 will be 0. If ci3 is the maximum of ci• , all three
weights will be 0.3̄. Due to the formulation as a linear program, Ci can
be calculated via a standard software solver like the one implemented in
Microsoft Excel.
In the third step of this MCIC approach, the Pareto classification scheme
described in Section 4.1 is used to group the SKUs. Thus, the SKUs are
grouped into three clusters according to their inventory risk index Ci . The
M cluster contains the SKUs with the highest risk whereas the N cluster
contains the SKUs with a lower risk. The SKUs with the relatively lowest
risk are grouped into the O cluster. The three letters M, N and O are
chosen arbitrarily, but may relate to major, noticeable, and ordinary risk.
Part II
Empirical Analysis
5 Simulation Design
This chapter introduces the empirical analysis. First, Section 5.1 describes
the used dataset and presents summaries of the variables. After this Sec-
tion 5.2 deals with the application of the forecast-based classification and
the MCIC approach. Section 5.3 describes the procedure of the inven-
tory simulation, and the details of the implementation are provided in
Section 5.4.
The first step of this analysis is the data preparation whereby implausible
values and inappropriate demand series are removed. Some demand series
contain values of −1, but there is no information about which event may
lead to negative demands. Therefore, those demands are set to 0. Addition-
ally, the described methods are unsuitable for seasonal goods like winter
tires or gingerbread. Therefore, SKUs which have a very long period of
zero demands (30 weeks or more) are removed from the dataset. Finally,
18 288 SKUs remain after this step.
The average SKU price ranges between e 0.14 and e 679.60. The median
is lower than the mean. Therefore, the distribution of the average prices is
right-skewed. 75% of the SKUs are sold for less than e 7.54 on average. The
distribution of the average demand per week is also right-skewed and ranges
between 0.06 and 2 658.00 pieces per week. 75% of the SKUs are sold less
than 16.25 times per period. The interpretation of the marketing campaigns
is slightly different because this variable does not have a quantitative scale.
The variable advertisement tracks the share of weeks in which a marketing
campaign hase taken place for the SKUs. Thus, there is no marketing
campaign for at least 50% of the SKUs in the considered time period. The
average share of periods with a marketing campaign is 8%, and there is at
least one SKU with a share of 78%.
Figure 5.1 shows the aggregation of the variables for the different SKUs.
Thus, the upper part of the graphic illustrates the revenue generated by the
18 288 SKUs whereas the lower part shows the share of SKUs for which a
marketing campaign has taken place within the given week. The blue lines
indicate a locally weighted smoothing. Due to Christmas sales, the revenue
has two peaks each at the end of a year. Additionally, the revenue of the
second half of 2002 is higher compared to the revenue in 2003. It ranges
between about e 600 000 and e 1 694 000, and after the 27th week of 2003
the smoothed revenue remains constant for the rest of the considered time
5.2 Classification 77
Revenue (e million)
1.50
1.25
1.00
0.75
Advertisment
0.12
0.10
0.08
0.06
period. The share of SKUs for which an marketing campaign has taken
place ranges between 4.5 and 12.7%. It can be seen that the smoothed
value floats slightly over time whereas the actual value varies significantly
from period to period.
5.2 Classification
As a first step, the 18 288 SKUs are grouped according to the forecast-
based classification method described in Section 4.2. The limit values of
the measures CV 2 and πY+ are optimized using the MASE. For every SKU
an one-step-ahead forecast is calculated using Exponential Smoothing (ES),
and the method developed in Syntetos and Boylan (2005) (SYN).10 These
forecasts are rated using the MASE. Thus, every SKU has two different
MASE values: one value which refers to the methods suitable for intermit-
tent demand and another which is not.
The limit values CV 2∗ and πY+∗ are optimized via a grid search in two
consecutive steps. First, several different average MASE values across all
10 The smoothing parameters of both methods are also optimized using the MASE.
78 5 Simulation Design
SKUs are calculated for different threshold values of πY+∗ . If the share of
positive demands (πY+ ) of a SKU is below the threshold πY+∗ , the MASE of
SYN is regarded. Otherwise, if πY+ ≥ πY+∗ the MASE of ES is used. The
minimal average MASE across all SKUs results from a threshold πY+∗ =
0.83. After this step the threshold of the squared coefficient of variation
CV 2∗ is optimized in the same way. The MASE of SYN is used if CV 2 is
below CV 2∗ and otherwise, the MASE of ES is used. The minimal average
MASE across all SKUs results at CV 2∗ = 0.5. These optimal values lead
to the final classification. If a SKU has a squared coefficient of variation
below 0.5 and a share of positive demands below 0.83, it is classified as
intermittent demand. These values match well with those proposed in
Syntetos and Boylan (2005). The group of intermittent demand contains
4 310 SKUs and comprise approximately 14.5% of all 29 807 SKUs.
M N O
3
CV 2
0
0.25 0.50 0.75 1.00
πY+
SKUs) there are a total of 258 600 different and independent simulations.
The remainder of this section describes the processes within each of those
simulations.
t=60
0 t t+1 t+2 T
past future
t=61
0 t–1 t t+1 T
past future
t=62
0 t–2 t–1 t T
past future
Forecast
Each simulation step starts with the calculation of the forecasts based
on six different methods described in Sections 3.2 and 3.3. These are
5.3 Simulation Procedure 81
namely the methods of Croston (CRO), Syntetos and Boylan (SYN), Leven
and Segerstedt (LEV), Teunter, Syntetos, and Babai (TEU), Exponential
Smoothing (ES) and integer-valued autoregressive processes (INAR). In
each step the smoothing parameters of the first five models and the model
order of INAR are estimated based on the past data. Then, the forecasts
and variances are estimated for the future L periods. In case of INAR L-
many future PMFs are estimated and aggregated using the Markov chain
approach presented in Section 3.3.4. The median of the L-many future
PMFs of INAR is used as point forecasts, whereas the inventory parameter
optimization is based on the aggregated PMF. Figure 5.4 shows the struc-
ture of this procedure over time. In every period for all methods L-many
forecasts are estimated based on the past observations.
t=60
0 t t+1 t+2 t+L
past future
t=61
0 t–1 t t+1 t+2 t+L
past future
t=62
0 t–2 t t+1 t+2 t+L
past future
Parameter Optimization
Based on these forecasts, the inventory parameters are optimized using the
different stochastic inventory models described in Section 2.3.3. All order
sizes D are calculated using the EOQ, but the determination of the reorder
points s differs among the methods. The determination of the reorder
point in case of the Croston-type models and the Exponential Smoothing
(CRO,SYN,LEV,TEU,ES) is based on additional assumptions of a lead
82 5 Simulation Design
time demand distribution. Thus, in this case the reorder point is calculated
based on the assumption of a normal or a gamma distributed demand
during the lead time. These resulting reorder points are rounded to the
next integer value in order to use them afterwards. In contrast, there is
no need of an additional distribution assumption in case of INAR, and the
resulting reorder points are, due to the definition, always integer valued.
To sum up this intermediate step, 11 different reorder points are calculated
in every simulation step whereas the order sizes are equal for all methods.
Inventory Simulation
20
15
pieces
yt
10 It
s
0
65 70 75 80 85
t
5.4 Implementation
Additionally, the future expectation and variance as well as the PMF fore-
cast are used in the optimization module. It is divided into a set of six
different methods which result all combinations of the two service levels
and the three distribution assumptions. The results of the five Croston-
type forecast models are used as inputs for the optimization based on the
gamma and normal distribution whereas the PMF forecast of the INAR
model is the input for the INAR optimization. The set of other input pa-
rameters is equal for all six optimization modules. It contains of the order
costs, the holding costs, the service level, and the lead time. The outputs
of this module are reorder points and order-up-to levels.
The actual inventory simulation is the last module. It uses the different
reorder points, order-up-to levels, and the demand data to simulate the
inventory level and position in each period as shown in Figure 5.5. Ad-
ditionally, this module calculates the achieved α- and β-service levels and
taken together with the inventory level those achieved service levels are
saved as results.
Forecast
Optimization
CRO
ES INAR
β-Service
α-Service
LEV
SYN
Identification
Inventory Simulation
TEU Model Gamma Distribution
Normal Distribution
INAR
Optimization
Parameter
Estimation
Parameter
MASE Results
whereas the C++ code implements the extensively often called functions,
e.g. the forecast calculation, the reorder point determination, and the cal-
culation of the MASE. In total the codebase of the algorithms amounts to
about 7 000 lines of code.
Data Node
The advantage of the inventory simulation over this example are the costs.
The inventory simulation was calculated using computing instances of a
cloud computing service provider. The 4 310 SKUs were processed in about
3 hours by two worker nodes, each having 16 CPU cores, and approximately
18 GB of data were generated.
6 Results
This chapter presents and analyzes this study’s results. Section 6.1 focuses
on the forecast performance of the different methods and shows three dif-
ferent analyses. First, the distribution of the MASE is examined in order
to give an impression of the overall method performance. Additionally, the
second analysis shows the percentage better forecast performance. Last,
the third analysis presents the distribution of the MASE in relation to the
probability of a positive demand and the squared coefficient of variation.
The results of the inventory simulation are presented in Section 6.2. They
are separated according to the service targets and present the achieved
service levels as well as the resulting inventory levels. Both subsections
provide four different analyses. First, the difference between the service
target levels and the achieved service levels are shown, separated according
to the different methods. Then, in order to provide information about the
economic results, the relation between the achieved service levels and the
inventory level is shown. The third analysis provides an overview of the
achieved service levels in relation to the probability of a positive demand
and the squared coefficient of variation of a SKU. Finally, each subsection
closes with an analysis of the relation between the resulting inventory level
and inventory risk cluster. Due to the vast amount of data created in this
study, the provided analyses only cover a subset. A more complete overview
is given in the appendix.
6.1 Forecasts
The first analysis considers the general performance of the applied fore-
cast methods separated according to the different inventory risk clusters.
Figure 6.1 illustrates a combination of a box and a violin plot of the one-
step-ahead MASE of the six different forecast methods.11 A lower MASE
indicates a better forecast, and a MASE of 1 indicates a forecast perfor-
mance which equals the performance of the naive forecast. The forecast
M N O
2.0
1.5
MASE
1.0
0.5
INAR
INAR
INAR
CRO
CRO
CRO
TEU
TEU
TEU
SYN
LEV
SYN
LEV
SYN
LEV
ES
ES
ES
method / horizon
CRO 23 62 30 32 20
SYN 77 69 37 52 30
LEV 38 31 36 30 19
TEU 70 63 64 59 33
ES 68 48 70 41 28
INAR 80 70 81 67 72
Figure 6.2 shows the results of this analysis. The numbers and filling color
indicate the share of SKUs in which the row method has a lower MASE
than the column method. The forecasting performance of CRO is poor
compared with the other methods. LEV is the only method which is worse
in terms of forecast performance compared with CRO. The results of SYN
are better. For 77% of the SKUs SYN produces better forecasts than CRO
and in 52% better forecasts than ES. LEV is worse in 69% compared with
SYN. TEU produces the best forecasts in the group of Croston-type models.
In 70% TEU is better compared with CRO, in 63% compared with SYN
90 6 Results
and in 64% compared with LEV. ES is the only method which has not
been developed for intermittent demand series in particular. Nevertheless,
ES produces forecasts which are superior compared to CRO (68%) and
LEV (70%). The forecast performance of INAR is comparatively the best
method. It excels CRO and LEV in about 80% of cases and SYN, TEU,
and ES in about 70% of cases. Figure 6.3 shows a hexagonal binning plot
0.4
0.3
0.2
MASE
0.1 1.50
0.0 1.25
CV 2
TEU ES INAR
1.00
0.5
0.75
0.4 0.50
0.3
0.2
0.1
0.0
.2 .4 .6 .8 .2 .4 .6 .8 .2 .4 .6 .8
πY+
The results in this chapter show that the methods, which regard the proper-
ties of intermittent demand, do not generally increase the forecast accuracy
compared with ES. LEV produces by far the worst forecasts whereas the
performance of INAR is superior compared with the other methods. SYN
is favorable compared with CRO, LEV, and ES. TEU produces the best
forecast in the group of Croston-type models. Additionally, there is no ev-
idence for a relationship between inventory risk and forecast performance.
Those three analyses are used because they all view the results from a dif-
ferent perspective. The main results of the inventory simulation are clearly
the achieved service levels, but exclusively using this perspective might lead
to incorrect conclusions. As previously stated, inventory management aims
to fulfill customer needs at minimal cost. Therefore, the second analysis
shows the relation between the achieved service levels and the inventory
level. This analysis also calculates the relative change in inventory level if
the service is increased. The third analysis connects the provided inventory
risk clustering with the resulting inventory levels on a SKU basis.
92 6 Results
Figure 6.4 illustrates the difference between the average achieved service
level and the target value. The columns separate the different lead times,
and the rows separate the two different order costs. The shapes mark the
assumed lead time demand distributions, and the methods are color-coded.
The black lines indicate a perfect match between the service target and the
average achieved service. In case of a short lead time L = 1 and low order
0.9
K=5
Normal
Gamma
0.8 INAR
avg. Service
ES
1.0
CRO
SYN
LEV
0.9 K = 25
TEU
INAR
0.8
Figure 6.4: Difference between achieved and target service in case of an α-service con-
straint
costs K = 5, the results are mainly close together. INAR has the highest
achieved service levels across all target values, and it stands out that TEU,
ES, and LEV in combination with a gamma distribution lead to the poorest
results. Even if the spread between them and the other methods decreases
at higher service targets, the spread does not disappear. For low service
targets (0.91) LEV/Gamma leads to a service of about 0.74, ES/Gamma
leads to a service of 0.77, and TEU/Gamma leads to an average service
of 0.85. All other methods lead to average service levels of approximately
6.2 Inventory Simulation 93
In case of a long lead time (L = 5), the change of the structure between
the service levels of L = 1 and L = 3 takes on. All the methods achieve a
lower service across all the target values and in this case INAR is the only
method which has a service level which meets the service constraints. All
the other methods for all the other service targets have a lower average
service level than the target value. The results of the methods based on
normal distribution spread far more widely than in case of shorter lead
times. TEU/Gamma and LEV/Gamma still have the lowest service.
94 6 Results
700
600
K=5
ES
CRO
Inventory (in 1.000 e )
500
SYN
400 LEV
TEU
INAR
1200
1100 Normal
K = 25
1000 Gamma
INAR
900
800
Figure 6.5: Achieved service vs. mean inventory levels (α-service target)
For higher order costs the achieved service levels are far better and closer.
Especially in case of L = 3 and L = 5 there are only slight differences.
Independent of the lead times and the service targets, INAR has an average
service of over 0.99 and therefore overshoots every target. In case of L = 1
and K = 25 the structure of the achieved service is very similar to the
L = 1, K = 5 case. Only TEU/Gamma, ES/Gamma, and LEV/Gamma
do not meet the service constraint. If L = 5, the distance between the
results of these three methods and the other methods declines, but for
high service targets INAR is the only method which meets the constraints.
TEU/Gamma results in the worst service.
The next analysis concerns the relationship between the achieved service
and the resulting mean inventory levels. Figure 6.5 is structured similar to
Figure 6.4 and shows the results of this analysis, but in contrast to the prior
figure, high values are no longer desired. In fact, a suitable method leads
to high service and low inventory levels. There is a trade off between those
two values, but in the sense of Pareto efficiency there are methods which
6.2 Inventory Simulation 95
are dominated by others because they achieve the same service levels with
higher inventories or lower service levels with the same inventory level.
It appears that for short lead times (L = 1) and low order costs (K = 5)
several methods lead to mainly the same results. One can distinguish
three different clusters. First, the results of all the methods based on the
gamma distribution except for SYN/Gamma are close together. The second
cluster consists of ES/Normal and TEU/Normal, and the third cluster
includes all the other methods. This third cluster dominates both other
clusters. Whereas the first cluster is dominated because of the poor service
levels, the second cluster is dominated because of the high inventory costs.
The results of ES/Normal and TEU/Normal demonstrate the difference
between the prior analysis and this one. By regarding the achieved and
target service levels exclusively, both ES/Normal and TEU/Normal lead to
sufficient results, but in relation to the mean inventory levels both methods
are dominated. Across all different service targets, ES/Normal results in
approximately 24%-36% higher inventories. If the service level is increased
by one percentage point the inventory level rises about 3.9% in the group
of non dominated methods.12
The spread between INAR and the other dominant methods increases if L =
5. TEU/Normal, TEU/Gamma, ES/Normal, ES/Gamma, and LEV/Gamma
12 Estimateof a log-linear regression model which regresses the inventory level of the
achieved service level of the dominant methods.
96 6 Results
are still dominated and are therefore not preferable. As previously men-
tioned, the achieved service of all the methods except for INAR is lower
compared with the shorter lead times. Due to the simultaneous reduction
in inventory levels. CRO and SYN remain dominant regardless of the used
lead time distribution. In this case the inventory level rises approximately
4.4% if the service increases by one percentage point.
The results in case of K = 25 are very similar overall. One can see that
the same methods are dominated, and that the methods group to the same
clusters. The main difference is the much higher inventory level, which
reaches from e 865 000 to e 1 050 000 among the dominant methods. The
rising separation between INAR and the other dominant models is also
noticeable. The inventory level rises by approximately 3.1% if L = 1, by
approximately 4.3% if L = 3, and by approximately 4.7% if L = 5 when
service levels increase by 1 percentage point.
0.4
0.3
0.2
0.1
0.0
ES/Normal INAR/INAR LEV/Gamma
0.5
0.4
0.3
0.2
0.1 Service
1.0
0.0 0.9
CV 2
0.2
0.1
0.0
TEU/Gamma TEU/Normal
0.5
0.4
0.3
0.2
0.1
0.0
.2 .4 .6 .8 .2 .4 .6 .8
πY+
Figure 6.7 shows the distribution of the mean inventory level separated
according to the different inventory risk clusters. It only contains the data
of the INAR model in case of K = 5, L = 5, and α = 0.95. The mean
inventory level of the SKUs within the M cluster have the widest spread.
The distribution is right-skewed, and the highest simulated mean inventory
level is about e 2 500. The median of this cluster is about e 250 and it can
be seen that the first quartile of the M cluster is above the third quartile of
the N cluster at about e 165. The distribution of the mean inventory levels
in the N cluster is more peaked. The median is about e 115, and the highest
mean inventory level in this cluster is about e 1 000. The distribution of the
O cluster is again more peaked, but it is bimodal. There are two noticeable
peaks above and below the median. The highest mean inventory level in
this cluster is about e 420 and the median is e 110. Overall, there is an
obvious relation between the mean inventory level and the inventory risk
cluster.
2500
2000
Inventory (in e )
1500
1000
500
0
M N O
Inventory risk cluster
Figure 6.7: Comparison of the resulting inventory level and the inventory risk clusters
This section presents the results of the inventory simulation based on the
β-service level. The structure corresponds to Section 6.2.1 and therefore,
100 6 Results
the first figure in this section shows the difference between the achieved
and the service target in case of a β-service constraint.
In case of short lead times (L = 1) and low order costs (K = 5) one can
distinguish between two different clusters of methods. On the one hand,
the methods based on the gamma distribution achieve a very high overall
service, but they overshoot the target. Additionally, except for the highest
service target one cannot notice an increase in the achieved service level
with rising service targets. On the other hand, the methods based on the
normal distribution and INAR perform better. For low service targets it
also overshoots, but with a lower difference and with a rising target an
increase in the achieved service can be seen. The results in the second clus-
ter are quite similar, but compared with the other methods TEU/Normal
leads to the lowest service levels.
With rising lead times (L = 3) the structure of the results changes signifi-
cantly. The achieved service of the group based on the gamma distribution
is reduced by approximately 6 percentage points. In comparison, the group
of methods based on the normal distribution performs worse in case of low
targets but except for TEU/Normal they perform better in case of high
targets. The result of INAR is the best among all the methods, and a gap
between INAR and all the other methods is noticeable.
In case of L = 5 and K = 5 this gap is even wider, but INAR still fits the tar-
get very well. All the other methods do not satisfy the service target. They
undershoot it by approximately 7 percentage points in case of ES/Normal
and approximately 13 percentage points in case of TEU/Normal.
If the order costs are high (K = 25), the difference between the methods is
much smaller. In case of L = 1 there is almost no change in the achieved
service along the different service level targets. The methods based on the
gamma distribution lead to service levels of approximately 0.98 across all
targets. The achieved service levels of the other methods are lower and also
almost constant at about 0.97.
6.2 Inventory Simulation 101
K=5
0.9 Normal
Gamma
INAR
avg. Service
0.8
1.0 ES
CRO
SYN
LEV
K = 25
0.9 TEU
INAR
0.8
Figure 6.8: Difference between achieved and target service in case of a β-service con-
straint
600
K=5
ES
500
CRO
Inventory (in 1.000 e )
400 SYN
LEV
300
TEU
1200 INAR
1100
Normal
K = 25
1000
Gamma
900 INAR
800
Figure 6.9: Achieved service vs. mean inventory levels (β-service target)
The next analysis, shown in Figure 6.9, considers the relationship between
the achieved β-service levels and the resulting inventory levels. In case of
short lead times the results are very close together. It is hard to distin-
guish among the different methods, but one can see that ES/Normal is
dominated. For low order costs, the inventory level is between e 430 000
and e 550 000 and rises approximately 3.6% if the service level is increased
by 1 percentage point. In case of K = 25 the inventory level is between
e 920 000 and e 1 030 000. The inventory level rises approximately 3.2% if
the service level is increased by 1 percentage point.
gets. This means that even if the achieved service of those methods is far
below the target, it can be met by increasing the input parameter of the
inventory simulation. Hence, the methods lead to service levels above 0.91
and are dominant. The inventory among the dominant methods is between
e 365 000 and e 640 000.
This anomaly also appears in case of L = 3 and K = 25. In this case the
inventory level is between e 850 000 and e 1 130 000 and it increases by 3.5%
if the service is increased by 1 percentage point. The results of the methods
based on the gamma distribution are close together and dominant, whereas
ES/Normal is dominated for all service level targets. Except for the highest
target, INAR is dominated.
In case of L = 5 and K = 25 the inventory level has the highest range be-
tween e 800 000 and e 1 200 000. Among the dominant methods the inven-
tory level increases by 4.5% if the service level is increased by 1 percentage
point. As in all the other cases ES/Normal is dominated, and the results of
the high service targets of LEV/Normal and LEV/Gamma dominate the
results of the low service targets of INAR. Additionally, CRO/Gamma and
SYN/Gamma lead to dominant strategies for low service level targets.
104 6 Results
0.4
0.3
0.2
0.1
0.0
ES/Normal INAR/INAR LEV/Gamma
0.5
0.4
0.3
0.2
0.1 Service
1.0
0.0 0.9
CV 2
0.2
0.1
0.0
TEU/Gamma TEU/Normal
0.5
0.4
0.3
0.2
0.1
0.0
.2 .4 .6 .8 .2 .4 .6 .8
πY+
The results of the last analysis are shown in Figure 6.11. It tracks the
resulting INAR inventory levels in case of L = 5 and K = 5 and a β-service
target of 0.95 separated according to the inventory risk clusters. It can
be seen, that the M-cluster gathers the SKUs with the highest inventory
level. This cluster has the highest range with a maximum inventory level
of approximately e 2200. The median inventory level is e 238, and the first
quartile is approximately e 150. The distribution of the inventory levels
within the N cluster is more peaked. The third quartile is at the same level
as the first quartile of the M cluster at approximately e 150. The interquan-
tile range of the inventory level within the N cluster is approximately e 85,
and the highest value in this cluster is e 640. Interestingly, there is only
106 6 Results
2000
Inventory (in e )
1500
1000
500
0
M N O
Inventory risk cluster
Figure 6.11: Comparison of the resulting inventory levels and the inventory risk clusters
6.3 Summary
Therefore, this study reveals a massive mismatch between the forecast per-
formance of these methods and the results of the inventory simulation.
There is an obvious relationship between the inventory performance and
the inventory risk clusters. The use of TEU leads to the worst results in
almost every case. Moreover, CRO, SYN, and even LEV lead to high ser-
6.3 Summary 107
In case of the β-service level targets and low order costs, the performance
of all the methods except for INAR is significantly reduced with rising lead
times. INAR matches the service target and along with CRO/Normal,
CRO/Gamma, and SYN/Normal, INAR leads to dominant results. The
distribution of the achieved INAR service level along with the probabil-
ity of a positive demand is homogeneous whereas the service levels of all
the other methods suffer from a higher probability of a positive demand.
Interestingly, LEV/Gamma and ES/Gamma show the opposite pattern in
case of an α-service target. The distribution of the service level separated
according to the inventory risk clusters shows that the clustering leads to
a suitable separation between the inventory levels of the M and N cluster,
but there is no significant difference between the N and O cluster.
7 Conclusion
These results imply several things. First, and most importantly, one must
not regard forecasts as a separate problem. If the forecast is used in in-
ventory management, the appropriate method should be selected based on
inventory performance and not based on statistical error measures. In ad-
dition, the use of appropriate methods for intermittent demand leads to
significantly improved results. In case of an α-service level target and low
Conclusion 111
M N O
2.0
1.5
MASE
1.0
0.5
INAR
INAR
INAR
CRO
CRO
CRO
TEU
TEU
TEU
SYN
LEV
SYN
LEV
SYN
LEV
ES
ES
ES
method / horizon
CRO 23 62 29 33 23
SYN 77 69 37 52 31
LEV 38 31 36 30 18
TEU 71 63 64 60 34
ES 67 48 70 40 29
INAR 77 69 82 66 71
CRO 19 56 20 30 17
SYN 81 62 25 48 21
LEV 44 38 38 37 14
TEU 80 75 62 64 25
ES 70 52 63 36 21
INAR 83 79 86 75 79
CRO 27 75 46 40 30
SYN 73 81 57 58 41
LEV 25 19 32 19 21
TEU 54 43 68 53 41
ES 60 42 81 47 38
INAR 70 59 79 59 62
CRO 22 55 20 29 19
SYN 78 63 25 48 26
LEV 45 37 37 36 17
TEU 80 75 63 63 31
ES 71 52 64 37 24
INAR 81 74 83 69 76
CRO 19 55 20 29 13
SYN 81 62 24 48 18
LEV 45 38 39 36 18
TEU 80 76 61 62 25
ES 71 52 64 38 19
INAR 87 82 82 75 81
CRO 26 75 46 39 28
SYN 74 80 58 58 41
LEV 25 20 33 18 18
TEU 54 42 67 53 39
ES 61 42 82 47 36
INAR 72 59 82 61 64
CRO 22 55 21 28 17
SYN 78 62 26 48 25
LEV 45 38 37 36 20
TEU 79 74 63 63 31
ES 72 52 64 37 24
INAR 83 75 80 69 76
0.4
0.3
0.2
MASE
0.1 1.50
0.0 1.25
CV 2
TEU ES INAR
1.00
0.5
0.75
0.4 0.50
0.3
0.2
0.1
0.0
.2 .4 .6 .8 .2 .4 .6 .8 .2 .4 .6 .8
πY+
0.4
0.3
0.2
0.1
0.0
Gamma / SYN Gamma / TEU INAR / INAR
0.5
0.4
0.3
0.2
Inventory
0.1
5000
0.0 4000
CV 2
0.3
0.2
0.1
0.0
Normal / SYN Normal / TEU
0.5
0.4
0.3
0.2
0.1
0.0
.2 .4 .6 .8 .2 .4 .6 .8
πY+
1500
Inventory (in e )
1000
500
0
M N O
Inventory risk cluster
Figure A.11: Inventory level separated according to inventory risk clusters
(CRO/Gamma)
1500
Inventory (in e )
1000
500
0
M N O
Inventory risk cluster
Figure A.12: Inventory level separated according to inventory risk clusters
(CRO/Normal)
2500
2000
Inventory (in e )
1500
1000
500
0
M N O
Inventory risk cluster
Figure A.13: Inventory level separated according to inventory risk clusters (ES/Gamma)
Appendix 119
3000
Inventory (in e )
2000
1000
0
M N O
Inventory risk cluster
Figure A.14: Inventory level separated according to inventory risk clusters (ES/Normal)
2000
Inventory (in e )
1500
1000
500
0
M N O
Inventory risk cluster
Figure A.15: Inventory level separated according to inventory risk clusters
(LEV/Gamma)
2000
Inventory (in e )
1500
1000
500
0
M N O
Inventory risk cluster
Figure A.16: Inventory level separated according to inventory risk clusters
(LEV/Normal)
120 Appendix
1500
Inventory (in e )
1000
500
0
M N O
Inventory risk cluster
Figure A.17: Inventory level separated according to inventory risk clusters
(SYN/Gamma)
2000
Inventory (in e )
1500
1000
500
0
M N O
Inventory risk cluster
Figure A.18: Inventory level separated according to inventory risk clusters
(SYN/Normal)
3000
Inventory (in e )
2000
1000
0
M N O
Inventory risk cluster
Figure A.19: Inventory level separated according to inventory risk clusters
(TEU/Gamma)
Appendix 121
3000
Inventory (in e )
2000
1000
0
M N O
Inventory risk cluster
Figure A.20: Inventory level separated according to inventory risk clusters
(TEU/Normal)
122 Appendix
0.4
0.3
0.2
0.1
0.0
Gamma / SYN Gamma / TEU INAR / INAR
0.5
0.4
0.3
0.2
Inventory
0.1 5000
0.0 4000
CV 2
0.3
0.2
0.1
0.0
Normal / SYN Normal / TEU
0.5
0.4
0.3
0.2
0.1
0.0
.2 .4 .6 .8 .2 .4 .6 .8
πY+
600
Inventory (in e )
400
200
0
M N O
Inventory risk cluster
Figure A.22: Compairson of the resulting inventory level and the inventory risk cluster
(CRO/Gamma)
Inventory (in e )
1000
500
0
M N O
Inventory risk cluster
Figure A.23: Compairson of the resulting inventory level and the inventory risk cluster
(CRO/Normal)
900
Inventory (in e )
600
300
0
M N O
Inventory risk cluster
Figure A.24: Compairson of the resulting inventory level and the inventory risk cluster
(ES/Gamma)
Appendix 135
4000
3000
Inventory (in e )
2000
1000
0
M N O
Inventory risk cluster
Figure A.25: Inventory level separated according to inventory risk clusters (ES/Normal)
1500
Inventory (in e )
1000
500
0
M N O
Inventory risk cluster
1500
Inventory (in e )
1000
500
0
M N O
Inventory risk cluster
600
Inventory (in e )
400
200
0
M N O
Inventory risk cluster
1500
Inventory (in e )
1000
500
0
M N O
Inventory risk cluster
2000
1000
0
M N O
Inventory risk cluster
2500
2000
Inventory (in e )
1500
1000
500
0
M N O
Inventory risk cluster
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