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Ch3 Forecasting - ME F316
Ch3 Forecasting - ME F316
Manufacturing Management
(ME F316)
BITS Pilani DSP
Pilani Campus
BITS Pilani
Pilani Campus
Forecasting Demand
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Forecasting
➢ What is forecasting?
➢ Why forecasting is needed?
➢ What kind of strategic role play the forecasting in
supply chain management?
➢ Which forecasting method is best suited for various
type of organization?
➢ How much accurate is the given forecast?
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Forecasting
Meteorologists forecast
the weather,
sportscasters and
gamblers predict the
winners of football
games, and
companies attempt to
predict how much of
their product will be
sold in the future
Forecasting
Forecast is a prediction of what will occur in the future.
Hopefully, the forecast will reduce uncertainty about the future
as much as possible, but it will never eliminate uncertainty.
A forecast of product demand is the basis for most important
planning decisions.
Supply chain functions include—
Scheduling
❖ Forecasting is an uncertain process.
Inventory
❖ It is not possible to predict
Production consistently what the future will be
Facility layout and design
Workforce
Distribution
Purchasing, etc.
BITS Pilani, Pilani Campus
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Bullwhip effect
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Forecasting components
Time Frame
Indicates how far into the future is
forecast
– Short- to mid-range forecast
• typically encompasses the
immediate future
• daily up to some months
– Long-range forecast
• usually encompasses a period
of time longer than 2 years
– The line between long range and
short forecasts are not always
distinct
monthly forecasts for printers are
constructed from 12 to 18 months hp’s long range forecasts for printers are
into the future, developed from 2 to 6 years into the future,
weekly forecasts for jeans are strategic plans for new and continuing
prepared for five years into the products go 10 years into the future
future. BITS Pilani, Pilani Campus
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Demand Behavior
Trend
– a gradual, long-term up or down
movement of demand
Random variations movements in
demand that do not follow a pattern
Cycle
– an up-and-down repetitive
movement in demand
Seasonal pattern
– an up-and-down repetitive
movement in demand occurring
periodically
Trend with seasonal pattern
– Demand for skis is seasonal,
there has been a upward trend in
past two decades
Forecasting Methods
Time series
– statistical techniques that use historical
demand data to predict future demand
Regression methods Causal forecasting method
– attempt to develop a mathematical
relationship between demand and factors
that cause its behavior
Qualitative Judgmental forecasting method
– use management judgment, expertise, and
opinion to predict future demand
Often called “the jury of executive opinion,” they are
the most common type of forecasting method for the
long-term strategic planning process
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Forecasting Methods
Weaknesses Can bias the forecast and Often quantifiable data are not
reduce forecast accuracy available. Only as the data on
which they are based
Forecasting Process
1. Identify the purpose 2. Collect historical data 3. Plot data and identify
of forecast patterns
7.
Is accuracy of No 8b. Select new forecast
forecast model or adjust
acceptable? parameters of existing
model
Yes
9. Adjust forecast based 10. Monitor results and
8a. Forecast over
on additional qualitative measure forecast
planning horizon
information and insight accuracy
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Quantitative Methods
Naive method
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ORDERS MOVING
MONTH PER MONTH AVERAGE 3
Jan 120 –
i=1
Di
Feb 90 – MA3 =
Mar 100 – 3
Apr 75 103.3
May 110 88.3 90 + 110 + 130
June 50 95.0
= 3
July 75 78.3
Aug 130 78.3
= 110 orders for Nov
Sept 110 85.0
Oct 90 105.0
Nov - 110.0
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ORDERS MOVING
MONTH PER MONTH AVERAGE 5
Jan 120 – Di
i=1
Feb 90 – MA5 =
Mar 100 – 5
Apr 75 –
May 110 – 90 + 110 + 130+75+50
= 5
June 50 99.0
July 75 85.0
Aug 130 82.0 = 91 orders for Nov
Sept 110 88.0
Oct 90 95.0
Nov - 91.0
Smoothing Effects
150 –
125 – 5-month
100 –
Orders
75 –
Actual
50 – 3-month
• 5 month moving average smooth out the fluctuations.
• 3 month average more closely reflect the most recent data.
25 –
• Forecasts using longer-period moving average are slower to react recent
changes.
0– | | | | | | | | | | |
Jan Feb Mar Apr May June July Aug Sept Oct Nov
Month
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Advantages/Disadvantages
n
WMAn = Wi Di
i=1
where
Wi = the weight for period i,
between 0 and 100 percent
Wi = 1.00
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= 103.4 orders
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Exponential Smoothing
Ft +1 = Dt + (1 - )Ft
where:
Ft +1 = forecast for next period
Dt = actual demand for present period
Ft = previously determined forecast for present period
= weighting factor, smoothing constant
0.0 1.0
If = 0.20, then Ft +1 = 0.20 Dt + 0.80 Ft
which means that our forecast for the next period is based on 20% of
recent demand (Dt) and 80% of past demand (Ft derived from past data)
If = 0, then Ft +1 = 0 Dt + 1 Ft = Ft
Forecast does not reflect recent data
If = 1, then Ft +1 = 1 Dt + 0 Ft = Dt
Forecast based only on most recent data
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Exponential smoothing
(α=0.30)
Exponential smoothing
FORECAST, Ft + 1
PERIOD MONTH DEMAND ( = 0.3) ( = 0.5)
1 Jan 37 – –
2 Feb 40 37.00 37.00
3 Mar 41 37.90 38.50
4 Apr 37 38.83 39.75
5 May 45 38.28 38.37
6 Jun 50 40.29 41.68
7 Jul 43 43.20 45.84
8 Aug 47 43.14 44.42
9 Sep 56 44.30 45.71
10 Oct 52 47.81 50.85
11 Nov 55 49.06 51.42
12 Dec 54 50.84 53.21
13 Jan – 51.79 53.61
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Exponential smoothing
Smoothening constant of 0.50 seems to react more strongly to changes in demand than
does the forecast with 0.30
70 –
60 – Actual = 0.50
50 –
40 –
Orders
= 0.30
30 –
20 – • When the demand is relatively stable without any trend, a small value of is more
appropriate.
• When actual demand displays an increasing or decreasing trend, a large value of will
10 –
react better and quickly
0– | | | | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10 11 12 13
Month BITS Pilani, Pilani Campus
Adjusted Exponential
Smoothing
It consists of exponential smoothing forecast with a trend adjustment factor
added to it:
Adjusted Exponential forecast:
AFt +1 = Ft +1 + Tt +1
where
T = an exponentially smoothed trend factor
Tt +1 = (Ft +1 - Ft) + (1 - ) Tt
where
Tt = the last period trend factor
= a smoothing constant for trend
0≤≤1
• It reflects the weight given to the most recent trend data.
• is usually determined subjectively based on the judgement of the forecaster
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Adjusted Exponential
Smoothing (β=0.30)
T3 = (F3 - F2) + (1 - ) T2
PERIOD MONTH DEMAND
= (0.30)(38.5 - 37.0) + (0.70)(0)
1 Jan 37
= 0.45
2 Feb 40
3 Mar 41 AF3 = F3 + T3 = 38.5 + 0.45
4 Apr 37 = 38.95
5 May 45
6 Jun 50 T13 = (F13 - F12) + (1 - ) T12
7 Jul 43
= (0.30)(53.61 - 53.21) + (0.70)(1.77)
8 Aug 47
9 Sep 56 = 1.36
10 Oct 52
11 Nov 55
12 Dec 54 AF13 = F13 + T13 = 53.61 + 1.36 = 54.97
Adjusted Exponential
Smoothing
FORECAST TREND ADJUSTED
PERIOD MONTH DEMAND Ft +1 Tt +1 FORECAST AFt +1
1 Jan 37 37.00 – –
2 Feb 40 37.00 0.00 37.00
3 Mar 41 38.50 0.45 38.95
4 Apr 37 39.75 0.69 40.44
5 May 45 38.37 0.07 38.44
6 Jun 50 38.37 0.07 38.44
7 Jul 43 45.84 1.97 47.82
8 Aug 47 44.42 0.95 45.37
9 Sep 56 45.71 1.05 46.76
10 Oct 52 50.85 2.28 58.13
11 Nov 55 51.42 1.76 53.19
12 Dec 54 53.21 1.77 54.98
13 Jan – 53.61 1.36 54.96
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Adjusted Exponential
Smoothing Forecasts
70 –
Adjusted forecast ( = 0.30)
60 –
Actual
50 –
40 –
Demand
30 – Forecast ( = 0.50)
20 –
xy - nxy
y = a + bx b =
x2 - nx2
where a = y-bx
a = intercept
where
b = slope of the line
n = number of periods
x = time period
y = forecast for x
x = = mean of the x values
demand for period x n
y
y = n = mean of the y values
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x(PERIOD) y(DEMAND) xy x2
1 37 37 1
2 40 80 4
3 41 123 9
4 37 148 16
5 45 225 25
6 50 300 36
7 43 301 49
8 47 376 64
9 56 504 81
10 52 520 100
11 55 605 121
12 54 648 144
78 557 3867 650
78
x = = 6.5
12
y = 557 = 46.42
12
b = xy - nxy = 3867 - (12)(6.5)(46.42) =1.72
x2 - nx2 650 - 12(6.5)2
a = y - bx
= 46.42 - (1.72)(6.5) = 35.2
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70 –
Linear trend line y = 35.2 + 1.72x
Forecast for period 13 y = 35.2 + 1.72(13) = 57.56 units
60 –
Actual
50 –
Demand
40 –
Linear trend line
30 –
• The trend line appears to reflect closely the actual data, that is to be a good fit
• It is assumed that all future forecasts will follow a straight line (it does not adjust to a
20 – change in the trend).
• This limits the use of this method to a shorter time frame (where the trend is constant)
10 – | | | | | | | | | | | | |
1 2 3 4 5 6 7 8 9 10 11 12 13
Period
Seasonal Adjustments
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Seasonal Adjustment
D1 42.0 D3 21.9
S1 = = = 0.28 S3 = = = 0.15
D 148.7 D 148.7
D2 29.5 D4 55.3
S2 = = = 0.20 S4 = = = 0.37
D 148.7 D 148.7
Seasonal Adjustment
For 2005
y = 40.97 + 4.30x = 40.97 + 4.30(4) = 58.17
SF1 = (S1) (F5) = (0.28)(58.17) = 16.28
SF2 = (S2) (F5) = (0.20)(58.17) = 11.63
SF3 = (S3) (F5) = (0.15)(58.17) = 8.73
SF4 = (S4) (F5) = (0.37)(58.17) = 21.53
DEMAND (1000’S PER QUARTER)
YEAR 1 2 3 4 Total
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Forecasting accuracy
Where,
t = the period number
Dt = demand in period t
Ft = the forecast for period t
n = the total number of periods
= the absolute value
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MAD Example
PERIOD DEMAND, Dt Ft ( =0.3) (Dt - Ft) |Dt - Ft|
1 37 37.00 – –
2 40 37.00 3.00 3.00
3 41 37.90 3.10 3.10
4 37 38.83 -1.83 1.83
5 45 38.28 6.72 6.72
6 50 40.29 9.69 9.69
7 43 43.20 -0.20 0.20
8 47 43.14 3.86 3.86
9 56 44.30 11.70 11.70
10 52 47.81 4.19 4.19
11 55 49.06 5.94 5.94
12 54 50.84 3.15 3.15
557 49.31 53.39
Dt - Ft
MAD = n
53.39
=
11
= 4.85
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|Dt - Ft|
MAPD =
Dt
• A lower percent deviation implies a more accurate forecast. The MAPD values
for other three forecasts are
• Exponential smoothing(α = 0.50):MAPD = 7.9%
• Adjusted exponential smoothing (α = 0.50, β = 0.30): MAPD = 7.5%
• Linear trend line: MAPD = 4.9%
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Cumulative error
Comparison of errors
• A positive value indicates low bias, and a negative value indicates high bias. A value close to
zero implies a lack of bias.
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Forecast control
Forecast control
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1 37 37.00 – – – –
2 40 37.00 3.00 3.00 3.00 1.00
3 41 37.90 3.10 6.10 3.05 2.00
4 37 38.83 -1.83 4.27 2.64 1.62
5 45 38.28 6.72 10.99 3.66 3.00
6 50 40.29 9.69 20.68 4.87 4.25
7 43 43.20 -0.20 20.48 4.09 5.01
8 47 43.14 3.86 24.34 4.06 6.00
9 56 44.30 11.70 36.04 5.01 7.19
10 52 47.81 4.19 40.23 4.92 8.18
11 55 49.06 5.94 46.17 5.02 9.20
12 54 50.84 3.15 49.32 4.85 10.17
6.10
TS3 = 3.05 = 2.00
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Forecast control
Regression methods
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y = a + bx
a = y-bx
b = xy - nxy
x2 - nx2
where
a = intercept (at period 0)
b = slope of the line
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Given the number of returning starters and the strength of the schedule,
the athletic director believes the team will win at least seven games next
year. Develop a simple regression equation for this data to forecast
attendance for this level of success.
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Correlation
Correlation in a linear regression equation is a measure of
the strength of the relationship between the independent
and dependent variables. The formula for the correlation
coefficient is
Correlation example
This value for the coefficient of determination means that 89.7% of the
amount of variation in attendance can be attributed to the number of wins by
the team
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Thank You
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