Free Engineering Tool #232
Spare Parts Reorder Point Calculator
Calculate when to reorder spare parts. ROP = daily demand × lead time + safety stock.
ROP = d×LT + SSSafety StockAuto-Calc
Results
Reorder Point (ROP)
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Pipeline Stock
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Inventory Value at ROP
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Reorder Point Formula
Safety stock protects against demand variability and supplier delays.
The inventory level at which a new order should be placed to receive stock before running out.
Simple: SS = Z × σ × √LT. For spare parts: typically 1-3 units based on criticality.
Use maximum monthly demand instead of average. Increase safety stock for critical items.
For lead times >6 months, consider keeping minimum 1 spare on shelf for critical items regardless of demand.
Balance holding cost (~20-25% of value/year) against stockout cost (production loss). For critical spares, stockout cost usually far exceeds holding cost.
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