Inventory Control Systems
A complete practical reference for selecting, designing and operating replenishment and inventory-control systems across stores, MRO, production, warehouse and line-side environments.
Inventory Control Systems Fundamentals
Inventory control systems determine how stock is monitored, when replenishment is triggered, how much is replenished, and how exceptions are controlled.
02Continuous Review System
A continuous review system monitors inventory position continuously and triggers replenishment when the control point is reached.
03Periodic Review System
A periodic review system checks inventory at defined intervals and replenishes according to the required inventory position.
04Fixed Order Quantity System
The fixed-order-quantity method replenishes a standard quantity whenever inventory position reaches the replenishment trigger.
05Fixed Order Interval System
The fixed-order-interval method reviews stock at predetermined intervals and determines the replenishment quantity at each review.
06Min-Max Control System
Min-Max control establishes a minimum/reorder level and a maximum target, with replenishment used to restore inventory toward the maximum.
07Reorder Point Control
Reorder Point control triggers replenishment when inventory position reaches the expected demand during lead time plus the required protection stock.
08Two-Bin System
The Two-Bin System separates available stock into a working bin and a reserve/replenishment bin to create a simple visual trigger.
09Three-Bin System
The Three-Bin System separates stock into current-use, reserve and incoming/replenishment-status quantities for clearer visual control.
10Kanban System
Kanban is a visual pull-control mechanism that authorizes replenishment or production based on actual consumption and defined container signals.
11Pull System
A pull system replenishes material because downstream consumption creates a requirement rather than because upstream supply is pushed by forecast alone.
12Push System
A push system releases material based primarily on planned requirements, forecasts, schedules or predetermined supply decisions.
13Push-Pull Hybrid System
Hybrid control combines planned upstream supply with downstream pull signals where each part of the material flow has different planning characteristics.
14JIT Inventory Control
Just-in-Time inventory control seeks to make material available close to the time and place of use while reducing unnecessary inventory and process waste.
15Order-Up-To System
The order-up-to system replenishes inventory toward a defined target level after each review or demand event.
16Base Stock System
A base-stock system maintains a defined inventory position or stock level appropriate to the service requirement and replenishment lead time.
17Visual Replenishment
Visual replenishment uses physical or digital signals such as cards, bins, labels, boards and status indicators to initiate replenishment.
18Point-of-Use Inventory
Point-of-use inventory positions required materials close to the operation or workstation while controlling quantity and replenishment.
19Line-Side Inventory
Line-side inventory supports production directly at the line while balancing availability, space, handling effort and inventory exposure.
20Supermarket Inventory System
A supermarket system holds controlled replenishment stock at a defined location from which downstream users withdraw material and create a replenishment signal.
21Milk-Run Replenishment
Milk-run replenishment uses scheduled collection and delivery routes to replenish multiple points of use with controlled frequency and quantities.
22Replenishment Parameters
Replenishment parameters include demand, lead time, safety stock, reorder point, minimum, maximum, order quantity, review period and service target.
23Inventory Position
Inventory position considers on-hand stock together with relevant open receipts and demand commitments when determining replenishment status.
24Replenishment Quantity
Replenishment quantity is the amount required to restore the inventory position toward the applicable target while respecting practical constraints.
25Service Level Control
Service-level control links replenishment parameters to the required probability or frequency of meeting material demand without stockout.
26Stockout & Exception Control
Exception control identifies shortages, overdue receipts, abnormal consumption, parameter failures and other conditions requiring management action.
27Control System Selection
Control-system selection should consider demand pattern, value, criticality, lead time, variability, consumption visibility, space and operational practicality.
28MRO Inventory Control Systems
MRO control applies replenishment methods to maintenance, repair and operating materials while accounting for criticality, intermittent demand and equipment risk.
29Kanban Container Sizing
Kanban container sizing determines the practical quantity and number of containers required to sustain consumption during replenishment lead time and variation.
30Two-Bin vs Kanban
Two-Bin and Kanban both use visual replenishment signals, but their control logic, authorization mechanism and operating context can differ.
31Inventory Control Systems in Excel
Excel can model inventory position, triggers, targets, replenishment quantities, exceptions and performance for controlled material populations.
32Inventory Control Systems in ERP
ERP systems support replenishment parameters, planning signals, stock status, open orders, reservations and exception reporting.
33Inventory Control KPIs
Inventory control performance can be monitored through availability, stockout rate, service level, fill rate, inventory accuracy, coverage and replenishment adherence.
34Inventory Control Governance
Governance defines ownership, parameter review frequency, master-data standards, approval rules, exception escalation and audit controls.
35Industrial Inventory Control Case Framework
A practical framework for selecting and implementing an inventory control method across MRO, production, stores and line-side materials.