Definition
Consumption history, variability, seasonality, trend and usable demand signals. This reference is designed for practical industrial stores, MRO, production and materials-management environments.
Objective
Convert transaction history into a usable demand signal for replenishment and planning.
Scope
Apply the method at item, category, location or plant level as appropriate. The control should connect planning, purchasing, stores transactions, physical verification and management review.
Required Inputs
- Issue history
- returns
- abnormal consumption
- shutdowns
- seasonality
- production plan.
Methodology
- Define the business requirement, scope and review period.
- Validate item master, consumption, stock and open transaction data.
- Calculate or classify using the defined method.
- Compare the result with criticality, supplier constraints and future demand.
- Assign an action owner, due date and review frequency.
- Monitor KPI movement and revise parameters when conditions change.
Formula / Control Logic
Worked Industrial Example
If valid six-month consumption is 18,000 units over 180 operating days, average daily consumption is 100 units/day.
Decision Rules
- Separate normal consumption from project, shutdown and one-time demand.
- Use a sufficiently long history for stable items.
- Flag abnormal spikes rather than silently averaging them.
Industrial Controls
- Authorized master-data and parameter changes
- ERP transaction discipline and document traceability
- Physical verification and reconciliation
- Exception reporting with named ownership
- Periodic management review of ageing, service and capital exposure
KPIs
Service
Availability, fill rate and stock-out performance.
Accuracy
Book-to-physical reliability and transaction quality.
Capital
Turnover, coverage, ageing, excess and dead stock.
Common Errors
- Using receipts as consumption.
- Including stock transfers as demand.
- Ignoring returns and reversals.
Excel / MIS Application
Useful fields: Item Code, Description, UOM, Opening Qty, Receipt Qty, Issue Qty, Closing Qty, Unit Rate, Annual Consumption, Current Stock, Open PO, Lead Time, Safety Stock, ROP, Min, Max, ROQ, ABC, VED, FSN, Ageing, Action.
Management Review Questions
- Which items require action now, and why?
- Are open orders aligned with actual requirement?
- Which exceptions are recurring and what is the root cause?
- Which parameter should be changed, and what evidence supports the change?