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
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Reorder Point (ROP)
Pipeline Stock
Inventory Value at ROP

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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