How To Calculate Re-order Level; A Step By Step Guide…

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Breathtaking design for home living.

How To Calculate Re-order Level; A Step By Step Guide…

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We’re not just another order fulfilment company. We’re the industry leader that delivers the highest quality B2B and B2C services to supercharge your business. If you’re looking to scale your business with world-class services, we’re here for you

What is a re-order level?

In a nutshell, a re-order level is the point at which a business can order new stock from their supplier or manufacturer.

In most cases, each SKU will have a specific re-order point, which occurs when the amount of a specific SKU falls to a pre-determined level.

Homeware; Exploring the growing market…

What is a re-order level?

In a nutshell, a re-order level is the point at which a business can order new stock from their supplier or manufacturer.

In most cases, each SKU will have a specific re-order point, which occurs when the amount of a specific SKU falls to a pre-determined level.

Homeware; Exploring the growing market…

What is the purpose of a re-order formula?

Holding the right or optimal amount of stock in storage at any given time is more difficult and not as simple as it sounds. There needs to be a good balance between being able to meet their customer demand while also avoiding unnecessary storage costs as a result of overstocking.

So, the purpose of a re-order level is to ensure that the risk of an item going out of stock is minimised. If you do run out of stock you may have to place orders on back-order, which can have a negative impact on your overall business, costs, and customer satisfaction.

In theory, a re-order level will prevent items from going out of stock should you receive a sudden surge in demand, delays from your supplier/manufacturer, a bulk order, etc. Calculating your re-order level can be calculated using what is known as the Re-order Point Formula.

Homeware; Exploring the growing market…

What is the re-order point formula?

The re-order point formula is quite simple, and is as follows;

Re-order point = total lead time demand + safety stock.

In order to successfully use this formula, you need to understand how to calculate your lead time demand and safety stock levels. Lets explore how you calculate the total lead time demand.

ROP in practice

Lets explore a couple of examples where ROP is used to calculate re-order levels.


Example A

  • You have a business selling a variety of notebooks. Your most popular lead has a re-order level of 30. You currently have 70 in stock, but you are hit with a spike in demand and end up selling 40 in under a week. This then takes you to your re-order level, which is 30. So it is time to place a new order with the supplier.


Example B

  • You have a business selling a variety of blankets. Your most popular lead has a re-order level of 50. You currently have 100 in stock, due to a drop in temperature as you enter the winter months. your orders increase to 50 for the week. This then takes you to your re-order level, which is 50. So it is time to place a new order with the supplier.

What is the purpose of a re-order formula?

Holding the right or optimal amount of stock in storage at any given time is more difficult and not as simple as it sounds. There needs to be a good balance between being able to meet their customer demand while also avoiding unnecessary storage costs as a result of overstocking.

So, the purpose of a re-order level is to ensure that the risk of an item going out of stock is minimised. If you do run out of stock you may have to place orders on back-order, which can have a negative impact on your overall business, costs, and customer satisfaction.

In theory, a re-order level will prevent items from going out of stock should you receive a sudden surge in demand, delays from your supplier/manufacturer, a bulk order, etc. Calculating your re-order level can be calculated using what is known as the Re-order Point Formula.

 

What is Kitting and Assembly?

Kitting and assembly is a fulfilment service that is offered by most 3PL companies. It is a process that involves compiling, or assembling different parts and components together to create one final product, bundle, or kit. It is worth noting that this then becomes one singular SKU rather than multiple.

Kitting and assembly gives you the chance to offer customised bundles, kits, and products, meaning that you can drive more sales through discounts, promotions, etc.

What is the re-order point formula? (ROP)

The re-order point formula is quite simple, and is as follows;

Re-order point = total lead time demand + safety stock.

In order to successfully use this formula, you need to understand how to calculate your lead time demand and safety stock levels. Lets explore how you calculate the total lead time demand.

ROP in practice…

Lets explore a couple of examples where ROP is used to calculate re-order levels.


Example A

  • You have a business selling a variety of notebooks. Your most popular lead has a re-order level of 30. You currently have 70 in stock, but you are hit with a spike in demand and end up selling 40 in under a week. This then takes you to your re-order level, which is 30. So it is time to place a new order with the supplier.


Example B

  • You have a business selling a variety of blankets. Your most popular lead has a re-order level of 50. You currently have 100 in stock, due to a drop in temperature as you enter the winter months. your orders increase to 50 for the week. This then takes you to your re-order level, which is 50. So it is time to place a new order with the supplier.

How to calculate total lead time demand…

Your lead time is the amount of days it takes for you to receive a certain product from the time you initially placed the order. So, to calculate your lead time demand, you can just multiple your average daily sales volume for that particular SKU.

Total lead time demand + lead time in days x average daily sales.

What is Kitting and Assembly?

Kitting and assembly is a fulfilment service that is offered by most 3PL companies. It is a process that involves compiling, or assembling different parts and components together to create one final product, bundle, or kit. It is worth noting that this then becomes one singular SKU rather than multiple.

Kitting and assembly gives you the chance to offer customised bundles, kits, and products, meaning that you can drive more sales through discounts, promotions, etc.

The Benefits of Calculating Your Re-order Level…

When it comes to ROP and using this method to calculate re-order levels, there are plenty of benefits. Lets explore how ROP can be beneficial for your eCommerce business…

The Benefits of Calculating Your Re-order Level…

When it comes to ROP and using this method to calculate re-order levels, there are plenty of benefits. Lets explore how ROP can be beneficial for your eCommerce business…

Improved Customer service…

As a customer, there is nothing more frustrating than wanting or needing a product that is no longer in stock. You have the option of placing their order on back-order, but this is not really an ideal solution either. Similarly, if you have a regular customer, and they frequently see that their desired item is out of stock, they are likely to look elsewhere. You will see an overall decline in customer satisfaction, customer retention, and customer loyalty.

Reduce your storage costs…

Not having the right amount of stock is going to cost you extra regardless of whether or not you’re overstocking or under-stocking. Understocking a product can lead to you missing out on sales (money), having to refund customers if you have placed them on back-order, or having to pay a ‘rush fee’ with your supplier or manufacturer (if that’s something they offer). Alternatively, having too much stock will cause unnecessary storage fees, and the flower your stock moves the more you pay in the long run.

Improved Customer service…

As a customer, there is nothing more frustrating than wanting or needing a product that is no longer in stock. You have the option of placing their order on back-order, but this is not really an ideal solution either. Similarly, if you have a regular customer, and they frequently see that their desired item is out of stock, they are likely to look elsewhere. You will see an overall decline in customer satisfaction, customer retention, and customer loyalty.

Reduce your storage costs…

Not having the right amount of stock is going to cost you extra regardless of whether or not you’re overstocking or under-stocking. Understocking a product can lead to you missing out on sales (money), having to refund customers if you have placed them on back-order, or having to pay a ‘rush fee’ with your supplier or manufacturer (if that’s something they offer). Alternatively, having too much stock will cause unnecessary storage fees, and the flower your stock moves the more you pay in the long run.

Exploring factors that can affect your re-order point calculation…

Exploring factors that can affect your re-order point calculation…

Product Demand

As mentioned, a sudden increase in demand can lead to you not having enough stock in place if you are unprepared. However, the ROP doesn’t take demand into account and therefore assumes that your demand level is consistent without any sudden fluctuations. This then means that your re-order point may not be as accurate.

For example, if you own a gifting business, your demand is obviously higher during holiday seasons, which will make your ROP less accurate. Therefore, it is more beneficial for you to use products that have a similar demand level throughout the entire year in order to get accurate figures for those specific products.

Lead Time

Similar to how demand can affect the accuracy of your re-order level, ROP assumes that items purchased from your supplier/manufacturer is consistent throughout the year.

If you have worked with the same manufacturer or supplier for a long period of time, you will probably have a good understanding of what their reliability is like which can help with calculating accurate lead times.

However, if you work with a number of different suppliers/manufacturers with varying lead times, or if they are not consistent or reliable, you may find that calculating your re-order level is difficult and inaccurate. Having a good, reliable supply chain is crucial.

Product Demand

As mentioned, a sudden increase in demand can lead to you not having enough stock in place if you are unprepared. However, the ROP doesn’t take demand into account and therefore assumes that your demand level is consistent without any sudden fluctuations. This then means that your re-order point may not be as accurate.

For example, if you own a gifting business, your demand is obviously higher during holiday seasons, which will make your ROP less accurate. Therefore, it is more beneficial for you to use products that have a similar demand level throughout the entire year in order to get accurate figures for those specific products.

Lead Time

Similar to how demand can affect the accuracy of your re-order level, ROP assumes that items purchased from your supplier/manufacturer is consistent throughout the year.

If you have worked with the same manufacturer or supplier for a long period of time, you will probably have a good understanding of what their reliability is like which can help with calculating accurate lead times.

However, if you work with a number of different suppliers/manufacturers with varying lead times, or if they are not consistent or reliable, you may find that calculating your re-order level is difficult and inaccurate. Having a good, reliable supply chain is crucial.

Improve your inventory management with TSP…

At TSP Fulfilment, we are an award winning 3PL company with over 20 years of industry experience, specialising in B2B and Amazon Fulfilment, as well as B2C Fulfilment.

We use industry leading technology to help you accurately track your inventory levels, allowing you to make informed decisions regarding your business. Explore our full range of services below…

Homeware; Exploring the growing market…

Improve your inventory management with TSP…

At TSP, we are an award winning 3PL company with over 20 years of industry experience, specialising in B2B and Amazon Fulfilment, as well as B2C Fulfilment.

We use industry leading technology to help you accurately track your inventory levels, allowing you to make informed decisions regarding your business. Explore our full range of services below…

80+ Global Fulfilment Centres

 

We integrate with over 150 platforms

 

18M Sq Ft of Global Warehouse Space

 

Our Range of Fulfilment Services

Storage, Pick and pack

At TSP we handle everything, starting with the storage, picking, and packing of your products.

We serve a range of markets so we have experience storing, picking, and packing a variety of different products, so we’ve got you covered regardless of what you sell.

Outsourcing your pick and pack with us will help free up your time, while also improving the entire process due to our highly experienced team of staff.

B2B and B2C Fulfilment

Regardless of whether you just do B2C or B2B, or a mixture of both, our team have the knowledge and resources required to successfully get your orders picked, packed, and shipped to your customer or chosen retailer.

While we handle your B2B and B2C fulfilment, you can focus on putting more time and money back into other areas of your business, such as your sales, marketing, and product development.

Shipping and logistics

After we pick and pack your orders, we ship them too.

We ensure you get better deals on shipping and packaging by letting you leverage our buying power, meaning you can save money and put it back into growing your business.

We also partner with a range of couriers, ensuring the needs of your business are being met through a diverse choice in reliable couriers.

Amazon FBM, FBA, SFP…

We are your one stop solution for all Amazon seller services, including FBA, FBM and SFP. With over 20 years of industry experience you can be assured that we are fully equipped to support you..

So regardless of what Amazon service you’re using, or if its a mix of all 3, we’ve got you covered. Check out our Amazon page for more information regarding our Amazon fulfilment services.

Inventory Management

Our cloud-based inventory management system, Mintsoft is easy to navigate and provides you with real time updates so you can always make informed decisions about your stock.

Returns Management

Returns are inevitable when it comes to your eCommerce business, but managing them correctly is a critical aspect on 3PL services. Here at TSP, we will handle the entire process from start to finish, helping you to main a high level of customer satisfaction.

Carbon Neutral Fulfilment

Are you a sustainable business? Looking to become more sustainable? Working with us means you can do your bit for the planet too, since we are a certified carbon neutral 3PL company.

Kitting, Bundling, and Assembly

Do you sell custom bundles or kits? We’ve got you covered. Our team is trained in kitting and bundle building, so you can be assured your customers will receive their orders in an accurate, timely manner.

Global Fulfilment

Do you require international shipping, or are you looking to expand into global markets? We’ve got you covered with our extensive network of couriers and global warehouses.

Explore our global fulfilment solutions page to see how we can help you dominate the global market, right from the heart of Newcastle.

Customs Bonded Warehouse

Here at TSP we are one of the very few Newcastle based order fulfilment companies with a dry bonded warehouse license.

Our network of freight forwarders means you can easily utilise the power of cross-border selling, allowing you to boost sales and drive growth.

Our Range of Fulfilment Services

Storage, Pick and pack

At TSP we handle everything, starting with the storage, picking, and packing of your products.

We serve a range of markets so we have experience storing, picking, and packing a variety of different products, so we’ve got you covered regardless of what you sell.

Outsourcing your pick and pack with us will help free up your time, while also improving the entire process due to our highly experienced team of staff.

B2B and B2C Fulfilment

Regardless of whether you just do B2C or B2B, or a mixture of both, our team have the knowledge and resources required to successfully get your orders picked, packed, and shipped to your customer or chosen retailer.

While we handle your B2B and B2C fulfilment, you can focus on putting more time and money back into other areas of your business, such as your sales, marketing, and product development.

Shipping and logistics

After we pick and pack your orders, we ship them too.

We ensure you get better deals on shipping and packaging by letting you leverage our buying power, meaning you can save money and put it back into growing your business.

We also partner with a range of couriers, ensuring the needs of your business are being met through a diverse choice in reliable couriers.

Amazon FBM, FBA, SFP…

We are your one stop solution for all Amazon seller services, including FBA, FBM and SFP. With over 20 years of industry experience you can be assured that we are fully equipped to support you..

So regardless of what Amazon service you’re using, or if its a mix of all 3, we’ve got you covered. Check out our Amazon page for more information regarding our Amazon fulfilment services.

Inventory Management

Our cloud-based inventory management system, Mintsoft is easy to navigate and provides you with real time updates so you can always make informed decisions about your stock.

Returns Management

Returns are inevitable when it comes to your eCommerce business, but managing them correctly is a critical aspect on 3PL services. Here at TSP, we will handle the entire process from start to finish, helping you to main a high level of customer satisfaction.

Carbon Neutral Fulfilment

Are you a sustainable business? Looking to become more sustainable? Working with us means you can do your bit for the planet too, since we are a certified carbon neutral 3PL company.

Kitting, Bundling, and Assembly

Do you sell custom bundles or kits? We’ve got you covered. Our team is trained in kitting and bundle building, so you can be assured your customers will receive their orders in an accurate, timely manner.

Global Fulfilment

Do you require international shipping, or are you looking to expand into global markets? We’ve got you covered with our extensive network of couriers and global warehouses.

Explore our global fulfilment solutions page to see how we can help you dominate the global market, right from the heart of Newcastle.

Customs Bonded Warehouse

Here at TSP we are one of the very few Newcastle based order fulfilment companies with a dry bonded warehouse license.

Our network of freight forwarders means you can easily utilise the power of cross-border selling, allowing you to boost sales and drive growth.

Collate your product details and connect your stores / market places

Link you into our preferred courier network

Take delivery of your stock, go live!



Collate your product details and connect your stores & marketplaces.



Link you into our preferred courier network.

Take delivery of your stock, go live!

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