Operations Management M103 Unit 2
Operations Management M103 Unit 2
Demand management
Demand management is the supply chain management process that balances the customers’ requirements
with the capabilities of the supply chain. With the right process in place, management can match supply
with demand proactively and execute the plan with minimal disruptions. The process is not limited to
forecasting. It includes synchronising supply and demand, increasing flexibility, and reducing variability.
This includes forecasting demand and synchronising it with production, procurement, and distribution
capabilities.
• A good demand management process can enable a company to be more proactive to anticipated
demand, and more reactive to unanticipated demand.
Demand management encompasses a range of activities aimed at aligning an organization’s supply chain
processes with customer demand. Its primary goal is to achieve a delicate balance between supply and
demand to optimize the use of resources and enhance customer satisfaction. Key aspects of demand
management include:
1. Demand Forecasting
Accurate demand forecasting is the cornerstone of demand management. Organizations use historical
data, market trends, and statistical models to predict future demand for their products or services.
2. Demand Planning
Once demand is forecasted, demand planning involves creating strategies and action plans to meet that
demand. It includes decisions about inventory levels, production schedules, and procurement.
3. Demand Shaping
Demand shaping involves influencing customer demand through marketing and pricing strategies. For
example, offering promotions or discounts during off-peak periods can help smooth demand.
4. Demand Sensing
Demand sensing refers to real-time monitoring of customer demand signals, such as point-of-sale data, to
respond quickly to changes in demand.
Demand management plays a crucial role in supply chain operations for several reasons:
1. Efficient Resource Allocation
By accurately forecasting and planning for demand, organizations can optimize the allocation of resources,
reducing the risk of overstocking or stockouts.
2. Cost Reduction
Efficient demand management can lead to cost savings by minimizing excess inventory carrying costs and
production inefficiencies.
3. Customer Satisfaction
Meeting customer demand promptly and reliably enhances customer satisfaction and loyalty.
4. Enhanced Responsiveness
Effective demand sensing and shaping enable organizations to adapt quickly to changing market conditions
and customer preferences.
5. Risk Mitigation
Demand management helps in identifying and mitigating risks associated with supply chain disruptions,
ensuring business continuity.
1. Data Analytics
Data analytics tools and techniques are essential for processing and analyzing large datasets to generate
accurate demand forecasts.
2. Collaboration
Collaboration among different departments, including sales, marketing, and supply chain, is crucial for
effective demand management.
3. Technology
Advanced software and technology solutions, such as demand planning software and Enterprise Resource
Planning (ERP) systems, facilitate demand management processes.
4. Continuous Improvement
Organizations should continuously review and refine their demand management processes to adapt to
changing market dynamics.
Achieving precise demand forecasts can be difficult, especially in dynamic markets with fluctuating
customer preferences.
Data Quality
The accuracy and quality of data used for forecasting are critical. Inaccurate data can lead to erroneous
forecasts.
3. Demand Variability
Managing demand for products with high demand variability can be challenging, as sudden spikes or drops
in demand are harder to predict and plan for.
4. Market Dynamics
External factors such as economic conditions, competition, and geopolitical e vents can impact demand and
require adaptive demand management strategies.
Demand Forecasting
Demand forecasting seeks to investigate and measure the forces that determine sales for existing and new
products. Generally companies plan their business – production or sales in anticipation of future demand.
Hence forecasting future demand becomes important. In fact it is the very soul of good business because
every business decision is based on some assumptions about the future whether right or wrong, implicit or
explicit. The art of successful business lies in avoiding or minimizing the risks involved as far as possible and
face the uncertainties in a most befitting manner .Thus Demand Forecasting refers to an estimation of most
likely future demand for a product under given conditions. Important features of demand forecasting It is
basically a guess work – but it is an educated and well thought out guesswork. It is in terms of specific
quantities It is undertaken in an uncertain atmosphere. A forecast is made for a specific period of time
which would be sufficient to take a decision and put it into action. It is based on historical information
and the past data. It tells us only the approximate demand for a product in the future. It is based on
certain assumptions. It cannot be 100% precise as it deals with future ex
Demand forecasting is needed to know whether the demand is subject to cyclical fluctuations or not, so
that the production and inventory policies, etc, can be suitably formulated Demand forecasting is generally
associated with forecasting sales and manipulating demand. A firm can make use of the sales forecasts
made by the industry as a powerful tool for formulating sales policy and sales strategy. They can become
action guides to select the course of action which will maximize the firm‟s earnings. When external
economic factors like the size of market, competitors attitudes, movement in prices, consumer tastes,
possibilities of new threats from substitute products etc, influence sales forecasting, internal factors like
money spent on advertising, pricing policy, product improvements, sales efforts etc., help in manipulating
demand. To use demand forecasting in an active rather than a passive way, management must recognize
the degree to which sales are a result not only of external economic environment but also of the action of
the company itself.
In the short run: Demand forecasts for short periods are made on the assumption that the company has a
given production capacity and the period is too short to change the existing production capacity. Generally
it would be one year period.
In Production planning: It helps in determining the level of output at various periods and avoiding
under or over production.
Helps to formulate right purchase policy: It helps in better material management, of buying inputs
and control its inventory level which cuts down cost of operation.
Helps to frame realistic pricing policy: A rational pricing policy can be formulated to suit short run
and seasonal variations in demand.
Sales forecasting: It helps the company to set realistic sales targets for each individual salesman
and for the company as a whole.
Helps in estimating short run financial requirements: It helps the company to plan the finances
required for achieving the production and sales targets. The company will be able to raise the
required finance well in advance at reasonable rates of interest.
Reduce the dependence on chances: The firm would be able to plan its production properly and
face the challenges of competition efficiently.
Helps to evolve a suitable labour policy: A proper sales and production policies help to determine
the exact number of labourers to be employed in the short run.
Accuracy: Accuracy is the most important criterion of a demand forecast, even though cent percent accuracy
about the future demand cannot be assured. It is generally measured in terms of the past forecasts on the
present sales and by the number of times it is correct.
Plausibility: The techniques used and the assumptions made should be intelligible to the management. It is
essential for a correct interpretation of the results.
Simplicity: It should be simple, reasonable and consistent with the existing knowledge. A simple method is
always more comprehensive than the complicated one
Durability: Durability of demand forecast depends on the relationships of the variables considered and the
stability underlying such relationships, as for instance, the relation between price and demand, between
advertisement and sales, between the level of income and the volume of sales, and so on.
Flexibility: There should be scope for adjustments to meet the changing conditions. This imparts durability
to the technique.
Availability of data: Immediate availability of required data is of vital importance to business. It should be
made available on an up-to-date basis. There should be scope for making changes in the demand
relationships as they occur.
Economy: It should involve lesser costs as far as possible. Its costs must be compared against the benefits
of forecasts
Quickness: It should be capable of yielding quick and useful results. This helps the management to take
quick and effective decisions. Thus, an ideal forecasting method should be accurate, plausible, durable,
flexible, make the data available readily, economical and quick in yielding results.
Statistical Methods:
1) Trends projection methods a) Fitting trend line by observation b) Least square liner regression c)
Time series analysis d) Moving average and annual difference e) Exponential Smoothing
Survey through Sample: A sample is a part of the total. In this method the forecaster selects a
sample or panel of consumers who would generate sense of the demand for the product. To state
in other words the forecaster selects a group of consumers from the total consumers of the
product and then carries out the forecast considering the responses given by the sample group. In
this method the consumers may be asked questions pertaining to various factors that would impact
the demand for the product. These factors would be determinants of demand like the incomes of
the consumers, prices of related products, price of the commodity itself and so on. How is the
sample survey done? Direct interviews could be done or the forecaster may prepare detailed
questionnaire to generate responses from the consumers. The urgency of forecast and availability
of funds also would determine the kind of approach the forecaster would like to go with while
conducting sample survey. Once the sample survey is done the forecaster would then derive the
overall demand for the product on the basis of overall demand of the sample group. Sample survey
is quite useful in case of new products as it would give direct responses from the end users. The
changes in preferences of consumers, impact of promotionalactivities could also be understood
through sample survey. The forecaster need not carry out the survey for total consumers and
needs to focus on the sample group only. Though cost friendly and less time consuming this
method is subject to certain shortcomings like sampling error and lack of exact answers. The
cooperation by the consumers also plays an important role in arriving at the conclusions. Method
of end use: This is yet another method through which demand forecasting could be done. What if
the product has more than one use? It means a product may be used as an intermediate product
(used in the production of other products), used for final consumption and can also be exported as
well as imported. So how is demand forecasted through this method? Here the demand for the
intermediate product could be estimated. The demand of exports net of imports could be
estimated and demand of final consumption could be predicted. It means that here the forecast
will be done for three components (for the firms using intermediate products, for the exporters
and importers and survey of the end users). This all parts are then added up to arrive at the final
forecast. One of the distinguishing features of this kind of survey is that it provides forecast sector
wise because the forecaster gets an idea of demand for the product through various uses since it is
carried out by considering multiple uses of the product. The major drawback of this method lies in
the requisite of accurate production plan for the coming times by the firms.
3)Expert’s Opinions
Under this method expert’s opinions are sought from specialists in the field, from inside and
outside of the organizations or the organization collects opinions from such specialists; views of
expert’s published in the newspaper and journals, wholesalers and distributors for the company’s
products, agencies and professional experts. These opinions and views are analyzed and
deductions are made there from to arrive at the figure of demand forecasts.
Advantages:
1. Forecasts can be done easily and speedily.
2. It is based on expert’s views and opinions hence estimates are nearly accurate.
3. The method is suitable where past records of sales are not available.
4. The method is economical because survey is done through collection of the data. The expenses
of seeking the opinions and views of experts are much less than the expenses of actual survey.
Dis-advantages:
1. Estimates for a market segment cannot be possible.
2. The reliability of forecasting is always subjective because forecasting is not based on facts.
B)Barometric Methods
In barometric methods historical or cross sectional data are used to forecast the future probable
demand of a particular product by applying statistical models and mathematical, equations. These
methods are considered to be superior techniques of demand estimation. The important statistical
methods used in demand estimation are; A. Trend Projection Method In trend analysis past data
about the dependent and independent variables is used to project the sales in the coming years
assuming that factors responsible for the past trends will continue to behave in similar manner in
future also as they did in the past in determining the magnitude and trend of sales of a product. In
this method a data set of past sales are taken at specified time, generally at equal intervals to
depict the historical pattern under normal conditions. On the basis of derived historical pattern, the
future sales of a company are project. The main aspect of this method lies in the use of time series
and changes in time series occur due to following reasons:-
1. Secular Trend: Secular Trend also known as long term trend indicate the gene ral tendency and
direction in which graph of a time series move in relatively over a long period of time. This can be
upward or downward trend, depending upon the behaviour.
2. Seasonal Trends: This trend reflects the changes in sales a company due to change in various
seasons or climates or due to festival season or sales clearance season etc. These changes are
repetitive in nature and related to twelve months period.
3. Cyclical Trends: These trends reflect the change in the demand for a product during diverse
phases of a business cycle i.e growth, boom, maturity, depression, revival, etc. 4. Random or
irregular trends: These changes arise randomly or irregularly due to unforeseen events such as
famines, earth quakes, floods, natural calamities, strikes, elections and crises. These changes take
place only in the short run and have their own impact on the sales of a firm. These trends cannot
be predicted. In trend projection method real problem is to separate and measure each of these
trends separately. In order to estimate the future demand of the product the impact of seasonal,
cyclical and irregular trends are eliminated from the data and only secular trend is used. The trend
in the time series can be eliminated by using any of the following method; I. Graphical Method, II.
The method of semi average, III. Moving average method and IV. The least square method I.
Graphical Method It is simplest method of trend projection. In this method periodical sales data is
plotted on a graph paper and a line is drawn through the plotted points. Then a free hand line is
drawn passing through as many points as possible. The direction of this free hand line or curve will
reflect the general trends whereas the actual trend line will show the seasonal, cyclical and
irregular trend.
Table-1
Sales data of XYZ Company
Years 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Sales(in 20 22 21 25 28 24 30 28 31 35 30
Lakhs)
Figure-1
Trend Projection Sales of XYZ Company
2006 22 (20+22+21+25+28)/5
2007 21 =23.2
2008 25
2009 28
2010 24 ---
2011 30 (30+28+31+35+30)/5
2012 28 =30.8
2013 31
2014 35
2015 30
Figure-2
Trend Projection Sales of XYZ Company
Table-3
Sales data of XYZ Company (₹, lakhs)
2005 20 -
2015 30 -
30
20
Year 2006 2007 2008 2009 2010 2011 2012 2013
The least square method is very popular method used in demand forecasting because it is very
easy and less expensive method.
Figure-4
Trend Projection Sales of XYZ Company
35
30
25
20
15
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
10
Years
5
0
Demand Forecasting For a New Product
Demand forecasting in case of new products is not easy as in case of established products. In case
new product the firms will not have any past experience or past data for this purpose. It requires
an intensive research of the economic and competitive features of the product should be made
to make efficient forecasts.
Professor Joel Dean, however, has suggested a few guidelines to make forecasting of demand for
new products.
a. Evolutionary approach
The demand for the new product may be considered as an outgrowth of an existing product. For
e.g., Demand for new Tata Indica, which is a modified version of Old Indica can most effectively be
projected based on the sales of the old Indica, the demand for new Pulsor can be forecasted based
on the sales of the old Pulsor. Thus when a new product is evolved from the old product, the
demand conditions of the old product can be taken as a basis for forecasting the demand for the new
product.
b. Substitute approach
If the new product developed serves as substitute for the existing product, the demand for the new
product may be worked out on the basis of a ‘market share’. The growths of demand for all the
products have to be worked out on the basis of intelligent forecasts f or independent variables that
influence the demand for the substitutes. After that, a portion of the market can be sliced out for the
new product. For e.g., A moped as a substitute for a scooter, a cell phone as a substitute for a land
line.In some cases price plays an important role in shaping future demand for the product.
Delphi method
The Delphi method is a type of forecasting model that involves a small group of relevant experts
who express their judgment and opinion on a given problem or situation. The expert opinions are
then combined with market orientation to come up with results and develop an accurate
forecast.
The Delphi method is performed in such a way that each expert is questioned individually to gather
their insights. This helps to prevent bias and ensures that the company’s forecast is based solely on
their own expert opinion.
Furthermore, other employees or outsourced parties collect, summarize, and analyze experts’
responses. They may pose additional questions to the participants who can then reconsider their
original responses in order to come up to a meeting point or final consensus that would be
beneficial to the company.
Highlights of Delphi method
Some of the highlights of this model include:
Freedom of expression — Since each expert is questioned individually, they have the freedom to
express their own opinion without feeling peer pressure,
Ability to make up their mind and give a second thought — The experts can change their opinion
and provide additional information in case they have reassessed the problem,
Consistent feedback — After each round, the participants are informed about the opinions of other
group members and then make discussions, and
Quantitative results — This type of model is qualitative in nature, however there is possibility to
analyze the results quantitatively.
When to use Delphi?
The Delphi method can be used to:
Predict trends in sales,
Forecast outcomes in economic development,
Identify risks and opportunities,
Create work breakdown structures, and
Compile a report from opinions.
Other situations where the Delphi method makes sense is when you:
Want to gather subjective statements from a larger group,
Find it difficult to perform a face-to-face discussion due to the group size,
Need to retain the anonymity of the participants, and
Feel there is a dominant person in the group who could interfere with the discussion.
Web-based forecasting is a method of using the internet to predict future events, trends, or
outcomes based on historical data and statistical analysis. Web-based forecasting systems can use
a variety of techniques to improve accuracy and efficiency, such as:
Machine learning
Econometric modeling
Regression analysis
Hybrid neural network
Fuzzy logic technique
Traditional statistical methods
Web-based forecasting systems can offer several benefits, including: Removing geographical
barriers, Reducing information dissemination costs, Enabling collaboration, and Preventing the
influence of leading personalities.
Some examples of web-based forecasting systems include:
Web-Based Intelligent Forecasting System (WIFS): A prototype software that uses a hybrid neural
network, fuzzy logic technique, and traditional statistical methods
Online Forecasting Calculator Tool: A tool from Call Centre Helper that can be used to make
forecasts
Collaborative Planning, Forecasting, and Replenishment (CPFR) is a web-based tool that helps
supply chain trading partners coordinate their planning and execution of customer demand. CPFR is
a strategic approach that involves collaboration between trading partners, such as manufacturers,
retailers, and suppliers, to improve supply chain efficiency and agility.
CPFR helps to:
Improve supply chain efficiency
CPFR can reduce inventory costs and enhance the performance of the entire supply chain.
Optimize sales forecasts
CPFR can help to optimize sales forecasts and respond to changes in market demand.
Reduce silos
CPFR can streamline supply chain planning activities and multiple S&OP processes.
CPFR involves trading partners sharing information and jointly planning key supply chain activities,
such as: Business planning, Sales forecasting, and Replenishment of finished goods and raw
materials.
The Collaborative Planning, Forecasting, and Replenishment (CPFR) process is a business concept
that involves trading partners working together to improve supply chain efficiency:
The CPFR process typically includes the following steps:
Planning
Trading partners work together to create a unified sales and production plan. This plan is based on
real-time data, historical information, and business analytics.
Forecasting
Trading partners work together to create collaborative sales forecasts. These forecasts take into
account historical sales data, market trends, and external factors.
Inventory management
Trading partners work together to monitor and manage inventory levels. This helps to coordinate
deliveries and minimize stockouts and overstock situations.
Other steps in the CPFR process include:
Developing an agreement on how communication will be carried out
Creating a joint business plan
Identifying exceptions and deviations in the sales forecast
Resolving exception items
Creating an order forecast
Identifying exceptions and deviations in the order forecast
Generating orders
CPFR Process Model Figure 8-1: CPFR Model (After J.D.Edwards White paper, 2003) The model as
shown in Figure 8-1 is a simplified version of the 9-step model. The model comprises:
The CPFR model enables significant scope and depth of collaboration across supply chains. CPFR
involves a number of business processes integrated between a number of supply chain partners eg
between a retailer and a supermarket. There is usually a few lead partners who select those
processes where CPFR is adopted. There is data exchange between the partners and include
suppliers taking responsibility for replenishment on behalf of their customer. Synchronized
forecasting is also involved in CPFR. The individual information systems are coordinated for
planning and replenishment pruposes. From the data of actual consumer demand extracted from
POS, product development, marketing plans, production planning and transport planning are
seamlessly integrated with forecasts.
Planning Phase In the planning phase, there are 2 stages:
Front-end Agreement The parties involved establish the guidelines and rules for the collaborative
relationship. The agreement includes a common basis for co-operation, trust and availability of
competency resources. All parties are bound to make available and ready these competencies and
resources for the system to work. The Business Intelligence modules allow partners to define and
measure specific KPIs. The agreement also includes mechanism to handle disagreements and
differences.
Forecasting Phase
The stages are: Sales-forecast Retailer point-of-sales data, causal information and information on
planned events are used by one party to create an initial sales forecast. This forecast is then
communicated to the other party and used as a baseline for the creation of an order forecast.
Identify exceptions for sales forecast Items that fall outside the sales forecast constraints set in the
front-end agreement are identified. The criteria for exceptions are stated in the Front-end
Agreement. Examples of such items are seasonal products.
Resolve / collaborate on exception items Exceptions are easily identified and messages are sent to
reconcile unusual items. Each contributor (partner, supplier, and customer) becomes an integral
part of the real-time collaborative process. The final enterprise forecast is the combination of the
most accurate and timely information available. The parties negotiate and produce an adjusted
forecast.
Create order forecast The order forecast relies on point-of-sale (POS) data, causal information,
and inventory strategies to generate a specific forecast that supports the shared sales forecast.
Identify exceptions for order forecast Items that fall outside the order forecast constraints set
jointly by the parties involved are identified.
Resolve / collaborate on exception items The parties negotiate (if necessary) to produce an
adjusted order forecast.
Replenishment Phase
The single stage is: Order Generation The final step in the CPFR process is generating the order
and promising the delivery. The order forecast is translated into a firm order by one of the parties
involved.
The essence of maintaining positive relationships with partners and customers is to deliver on
promises.
5. Benefits of CPFR Improved customer service trough better forecasting techniques More
reliable forecasting allows a more effective way to anticipate consumer demand across the entire
supply chain and therefore allow the business to plan production capacity accordingly. Risks for
stock-outs is reduced which improves customer fulfillment orders which thereby increases
revenue, delivery and improved customer service. Lower Inventories for higher profits
Accurate predictions of demand as mentioned before will reduce stock-outs and provide a more
efficient understanding of production needs. Safety stock inventory for over production would be
reduced which decreases carrying costs, storage space and potential spoilage/obsolescence.
Additionally, there is improved material flow and release of working capital that can be used in
other areas of the production instead of being tied up in inventory.
Improved ROI on Technology investment Effective CPFR technology solutions benefit both
manufacturers and retailers from reduced overhead costs because several inefficiencies are
eliminated, i.e., antiquated manual processes, custom integrations of different partner IT systems
and information searching of multiple sources/systems. Improved relationships between trading
partners
Develop when collaboration takes place. Trading partners gain a better understanding of
respective businesses by regularly exchanging information and establishing direct communication
on channels and create a win-win situation.
Cost reduction Will occur when production schedule and agreed forecasts are aligned. Costs are
reduced by decreasing set-up times, effort duplication and variations. There is also efficient
production capacity utilization since planning information is more reliable.
Cons of CPFR
Implementation Complexity:
CPFR implementation can be complex and resource-intensive. Adopting collaborative planning
requires not only the integration of technology but also changes in organizational processes and
culture. This complexity can pose challenges, particularly for businesses with existing systems that
may not easily align with CPFR principles.
Data Accuracy and Trust Issues:
Reliance on accurate and timely data is vital for the success of CPFR. Issues such as data
inaccuracies, discrepancies, or a lack of trust between trading partners can undermine the
effectiveness of collaborative planning. If one party doubts the accuracy of shared information, it
can lead to suboptimal decision-making and collaboration breakdowns.
Dependency on Partner Cooperation:
CPFR relies on the active cooperation and engagement of all trading partners involved in the supply
chain. If one partner fails to actively participate or share relevant information, it can disrupt the
collaborative planning process. Achieving a synchronized and effective supply chain requires
commitment and coordination from all parties, and any lack of alignment can hinder the desired
outcomes.
What is Forecast Accuracy?
Forecast accuracy is the means of measuring how well a demand forecast has predicted actual
outcomes or values of sales. Additionally, forecast accuracy ascertains the reliability and
effectiveness of one’s forecasting models and techniques currently in-use. Determining one’s
forecast accuracy provides more insight into a company’s market, allowing for more effective
decision-making with regard to stock numbers and levels. The future benefit of ensuring that the
right amount of inventory is available at the right time helps mitigate any issues that could cause
major revenue losses such as over or understocking.
Forecast accuracy is also commonly used across various fields, such as sales forecasting, demand
planning, and financial forecasting. In sales forecasting, accurate predictions help organisations
estimate future sales volumes, optimise inventory levels, and streamline production processes. Like
sales forecasting, demand planning places its focus on stock levels, ensuring the availability of
products to meet customer demands without running into excess inventory or stock-out issues.
Financial forecasting utilises forecast accuracy to make informed monetary decisions: budgeting,
resource allocation, and investment strategies.
Case Study
Given the following data:
Period Number of Complaints
1 60
2 65
3 55
4 58
5 64
Prepare a forecast for period 6 using each of these approaches