Description

This curriculum spans the technical and operational complexity of a multi-year internal capability program focused on end-to-end service parts flow, comparable to sustained advisory engagements addressing demand forecasting, multi-echelon inventory control, and repair network design across global operations.

Module 1: Demand Forecasting for Intermittent Parts

Selecting between Croston’s method and Teunter-Syntetos-Babai (TSB) for slow-moving SKUs based on historical transaction sparsity and obsolescence risk.
Adjusting forecast models to account for known engineering change orders (ECOs) that invalidate historical usage patterns.
Integrating field failure reports and warranty claims into demand signals when transaction volume is insufficient.
Handling demand spikes caused by fleet-wide recalls without overfitting baseline forecasts.
Validating forecast accuracy using holdout samples across multiple locations with differing service level agreements.
Managing forecast overrides from regional service managers while maintaining auditability and model integrity.

Module 2: Inventory Position Visibility and Accuracy

Reconciling discrepancies between ERP inventory records and physical counts in multi-echelon networks with cross-docked transfers.
Implementing cycle counting protocols for high-value, low-turnover parts without disrupting field technician operations.
Configuring real-time integration between warehouse management systems (WMS) and service parts planning engines.
Defining ownership of in-transit stock between depots and mobile technicians for service level calculations.
Handling serialized part tracking for regulatory compliance and warranty validation in aerospace and medical equipment.
Establishing data governance rules for master data synchronization across global subsidiaries with local procurement.

Module 3: Multi-Echelon Inventory Optimization (MEIO)

Determining optimal stocking levels at central warehouses versus forward stocking locations based on replenishment lead time variance.
Allocating constrained inventory during supply shortages using priority rules tied to customer SLAs and equipment criticality.
Modeling lateral transshipments between regional depots with asymmetric lead times and capacity constraints.
Setting safety stock parameters at each echelon to meet system-wide service targets without local overstocking.
Simulating the impact of consolidating distribution centers on total network lead time and fill rate performance.
Calibrating MEIO models with actual repair turnaround times from third-party maintenance providers.

Module 4: Supplier and Procurement Lead Time Management

Negotiating consignment inventory agreements with long-lead-time suppliers to shift ownership without increasing working capital.
Monitoring supplier on-time delivery performance and triggering contingency plans for critical parts with single sourcing.
Implementing blanket purchase orders with scheduled call-offs to reduce order processing delays.
Managing lead time variability from offshore suppliers due to customs, port congestion, or air freight availability.
Validating supplier-provided lead time estimates against actual receipt data across multiple order cycles.
Coordinating with procurement to qualify alternate suppliers for high-risk parts without compromising quality certifications.

Module 5: Repair and Reverse Logistics Network Design

Determining economic repair thresholds for parts based on core return lead time and refurbishment cost.
Routing failed parts to regional repair centers versus OEMs based on turnaround time and warranty status.
Designing return packaging and labeling standards to reduce processing time at receiving docks.
Tracking repair cycle time by failure mode to identify chronic reliability issues affecting part availability.
Managing core deposits to improve return rates without creating customer billing disputes.
Integrating repair status updates into the service parts planning system to reduce safety stock requirements.

Module 6: Service Level and Stockout Cost Modeling

Assigning differential stockout costs to parts based on equipment downtime revenue impact and customer contract terms.
Setting target service levels by part criticality, balancing inventory investment against operational risk.
Quantifying the cost of emergency air freight for critical part shortages in global service networks.
Adjusting service targets for parts supporting safety-critical or regulated equipment.
Measuring actual downtime hours caused by part unavailability using field service management system data.
Aligning inventory policies with service contract renewal risk and customer satisfaction metrics.

Module 7: Technology Integration and System Configuration

Configuring service parts planning software to handle substitution rules for interchangeable or superseded parts.
Mapping legacy part numbers to new ERP material masters during system migration without disrupting replenishment.
Automating reorder triggers based on dynamic min/max levels adjusted for forecast changes and backlog.
Integrating IoT sensor data from equipment fleets to predict part failure and pre-position inventory.
Designing user roles and approval workflows for manual inventory adjustments and emergency requisitions.
Validating system-generated replenishment recommendations against planner overrides to refine algorithms.

Module 8: Performance Monitoring and Continuous Improvement

Tracking lead time by component: order processing, supplier fulfillment, transportation, and receiving inspection.
Conducting root cause analysis on recurring stockouts using Pareto analysis of part, location, and supplier.
Measuring forecast bias and mean absolute percentage error (MAPE) by part category and horizon.
Reviewing inventory turns and days of supply for excess and obsolete (E&O) parts with financial stakeholders.
Running periodic what-if scenarios to assess impact of lead time reductions on safety stock and service levels.
Establishing cross-functional governance forums to resolve systemic delays in procurement, repair, or distribution.