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try itoperationsdraft · [DATE]

When should you reorder?

In most small companies, someone reorders when the shelf looks almost empty. By then it's often late: the supplier needs time, and customers don't wait. Here's how I think about it, and a tool to try.

the idea

Reorder when the stock you have left covers what you'll sell while you wait for the delivery, plus a margin for surprises. That level is the reorder point.

reorder pointdaily demand × lead time + safety stock

The first part is simple arithmetic. The margin is where the decisions are: too small and you run out, too big and money sits on the shelf.

Try it with your numbers

90 days of one product, with demand that moves up and down like real sales.
stock using the margin out of stock reorder point
day 1day 45day 90

how big a margin?

The textbook links the margin to how much demand varies and to the service level you want, the share of cycles in which you don't run out:

safety stock = z × σ × √Lz: service level · σ: daily demand variation · L: lead time

A small company rarely has clean data for σ on day one. I'd start simpler: a few days of cover, then measure how often you actually run out and how much stock sits still, and adjust. Ask, connect, measure.

And not every product deserves the same care. A handful usually make most of the sales: give those a bigger margin and keep the rest lean.

in practice
I'm measuring this right now.Before changing any rule in our warehouse, I'm recording stock-outs and slow stock for every product. The before and after will become a case study. [MONTH]See the cases →