In brief
A stock rule should be based on observed consumption and replenishment risk, not an arbitrary number of pallets or weeks.
Separate normal demand, peak variation and contingency stock, then review the rule as usage or lead time changes.
Build a reliable usage baseline
Use issues or purchases over a representative period and reconcile unusual projects, stock adjustments and waste. Separate hand and machine films and any site-specific formats.
Measure replenishment time
Record the complete time from approved order to usable stock, including internal approval, supplier lead time, delivery booking and receipt. Use actual variability rather than the best recent delivery.
Define cycle stock and contingency separately
Cycle stock supports expected demand between deliveries. Contingency stock addresses stated risks such as demand peaks or delayed replenishment. Document the scenario and owner so buffer stock does not grow without review.
Set a transparent reorder trigger
A simple starting model is expected usage during replenishment time plus an agreed buffer. State units clearly—rolls, cases or net kilograms—and avoid mixing purchase and consumption units.
Check storage and continuity constraints
Balance order economics with racking space, handling, film storage guidance and cash tied in stock. Review alternative supply routes without assuming uncontracted availability.
| Input | Evidence | Review trigger |
|---|---|---|
| Demand | Usage by week and film type | Volume or process change |
| Lead time | Order-to-usable-stock history | Supplier or delivery change |
| Buffer | Named risk scenario | Risk or service review |
| Capacity | Safe designated storage | Layout or stock-format change |
Practical checklist
- Separate film types and sites
- Reconcile usage with stock movements
- Measure full replenishment time
- Document the buffer scenario
- Set owners and review dates
- Follow product-specific storage guidance