This is the second article in a series on setting safety-stock to address supply variation. Part 1 can be found here. Analyzing Supplier Lead Time To get an accurate performance picture, we must analyze supplier lead time for each item and overall. Keep in mind that lead time must accurately define the current state as it actually is, not an ideal or pending future state. Far too many inventory managers fall into the trap of conflating lead time goals and actual lead time, and then knowingly or unknowingly trying to make up the gap with safety-stock. Don’t do this! The purpose of supply-related lead-time safety stock is to mitigate the risks of actual supply variation. Thus, we must accurately quantify lead time variation. In that effort, 2 key metrics that give us a solid grasp of lead time variation are average lead time and lead time standard deviation. We must calculate both.
Average lead time and lead time standard deviation can be interesting, but don’t give us a full picture of lead time volatility on their own. Once we have these 2 metrics, we must compare them to one another in order to determine lead-time risk. To do that, we simply divide average lead time by lead-time standard deviation to get lead-time standard deviation percent (lead time risk). The result quantifies lead time standard deviation as a percent of average lead time. Typically, safety stock is not justified anytime lead time standard deviation is 10 percent or less of average lead-time. Don’t forget, that lead-time deviation is the product of late and early receipt, but only late receipts create a risk of stock out. That said, if the result is greater than 10 percent you should contact your supplier and request that they commit to reasonable lead-time. If they continue to be unreliable, issue a warning, before seeking out a more reliable partner. Setting Supply Variation Safety-Stock
With the above in mind, don’t forget to always communicate respectfully with all suppliers. Remember, good suppliers are partners to collaborate with not enemies to vanquish. Respectful communication includes holding your organization to the same standards as your suppliers. Reliable suppliers should commit to standard lead times, but lead time us something that you, the OEM, must adhere to as well. If a supplier’s standard lead-time is 20 days, but you ask them to expedite 45% of all orders, it will appear as if they exhibit greater lead-time variation and might simultaneously suggest in an average lead-time that’s lower than the standard. This can cause a great deal of confusion during supplier negotiations. 3 Common Causes of Expedited Shipments
Safety Stock for Supplier Quality If your reject rate is above 1 percent, you should determine the percentage of orders containing any rejects. It’s recommended to aim for an order reject rate of less than 2 percent but no more than 5 percent. Is Safety Stock Really Needed to Address Quality? If your reject rate is above 1 percent, you should determine the percentage of orders containing any rejects. It’s recommended to aim for an order reject rate of less than 2 percent but no more than 5 percent. Is Safety Stock Really Needed to Address Quality? If entire orders are rejected regardless of the percent of the order that represents bad items, then you will need to set safety stock to address quality issues. In such cases, you have a few options in order of priority.
Supplier Target Safety-Stock Summary Think of your suppliers as collaborative partners. Remember to communicate expectations and measures to your suppliers. Good suppliers are able and willing to address any delivery and quality issues that may arise. Any time additional safety stock is necessary to account for supply variation, it should be the supplier’s burden to bear. Clearly share your expectations and be prepared to replace the supplier if conditions aren’t met within a clearly defined and reasonable time frame. Carrying more safety stock should never be considered a long-term resolution. That does it for part 2 of this 2-part series on supply variation safety-stock. |