{"id":100232,"date":"2026-02-15T20:28:56","date_gmt":"2026-02-15T20:28:56","guid":{"rendered":"https:\/\/vibromera.eu\/?post_type=calculator&#038;p=100232"},"modified":"2026-07-15T13:34:45","modified_gmt":"2026-07-15T13:34:45","slug":"spare-parts-inventory","status":"publish","type":"calculator","link":"https:\/\/vibromera.eu\/lt\/calculators\/spare-parts-inventory\/","title":{"rendered":"Reorder-Level Arithmetic Worksheet"},"content":{"rendered":"<p><script type=\"application\/ld+json\">{\"@context\":\"https:\/\/schema.org\",\"@type\":\"WebApplication\",\"name\":\"Controlled Reorder-Level Arithmetic Worksheet\",\"description\":\"Add controlled expected demand during replenishment lead time and controlled safety stock. No automatic safety-stock model, rounding, order quantity, cost or critical-spare verdict.\",\"url\":\"https:\/\/vibromera.eu\/calculators\/spare-parts-inventory\/\",\"applicationCategory\":\"BusinessApplication\",\"operatingSystem\":\"Any\",\"isAccessibleForFree\":true,\"inLanguage\":\"en\"}<\/script><\/p>\n<style>\n.vbm232{--ink:#172235;--muted:#556276;--line:#d8e0e9;--soft:#f4f7fa;--blue:#135ca8;--blue2:#0d447e;--amber:#8a5700;--amber-bg:#fff7df;--red:#a52828;--red-bg:#fff0f0;--green:#17613a;--green-bg:#edf9f1;max-width:1040px;margin:0 auto;padding:18px 14px 44px;color:var(--ink);font:15px\/1.55 system-ui,-apple-system,\"Segoe UI\",sans-serif}.vbm232 *{box-sizing:border-box}.vbm232 h1,.vbm232 h2,.vbm232 h3{line-height:1.2}.vbm232 h1{font-size:clamp(27px,4vw,42px);margin:8px 0 12px}.vbm232 h2{font-size:22px;margin:0 0 16px}.vbm232 p{margin:8px 0}.vbm232 a{color:var(--blue)}.vbm232-header{text-align:center;padding:32px 18px 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#edb5b5;border-radius:8px;background:var(--red-bg);color:var(--red);font-weight:650}.vbm232-error.show{display:block}.vbm232-results{display:none}.vbm232-results.show{display:block}.vbm232-result-grid{display:grid;grid-template-columns:repeat(3,minmax(0,1fr));gap:12px}.vbm232-result{border:1px solid var(--line);border-radius:10px;background:var(--soft);padding:13px}.vbm232-result.primary{border-color:#7dacda;background:#eef6ff}.vbm232-result-label{color:var(--muted);font-size:12px;font-weight:700;text-transform:uppercase;letter-spacing:.06em}.vbm232-result-value{font:700 17px\/1.35 ui-monospace,SFMono-Regular,Consolas,monospace;overflow-wrap:anywhere;margin-top:4px}.vbm232-result.primary .vbm232-result-value{font-size:22px;color:var(--blue2)}.vbm232-status{margin-top:14px;border-left:4px solid var(--green);background:var(--green-bg);padding:12px 14px}.vbm232-formula{overflow-x:auto;border:1px solid var(--line);border-radius:9px;background:var(--soft);padding:12px 14px;margin:10px 0;font:600 14px\/1.7 ui-monospace,SFMono-Regular,Consolas,monospace}.vbm232 table{width:100%;border-collapse:collapse;margin:12px 0}.vbm232 th,.vbm232 td{border:1px solid var(--line);padding:9px 10px;text-align:left;vertical-align:top}.vbm232 th{background:#eaf0f6}.vbm232 ul{padding-left:22px}.vbm232 details{border-top:1px solid var(--line);padding:11px 0}.vbm232 summary{cursor:pointer;font-weight:760}.vbm232-small{font-size:13px;color:var(--muted)}\n@media(max-width:700px){.vbm232{padding-left:10px;padding-right:10px}.vbm232-card{padding:16px}.vbm232-grid,.vbm232-result-grid{grid-template-columns:1fr}.vbm232-field.full{grid-column:auto}.vbm232 table{display:block;overflow-x:auto}}\n<\/style>\n<p><main class=\"vbm232\"><\/p>\n<header class=\"vbm232-header\">\n<p class=\"vbm232-kicker\">Controlled expected lead-time demand \u00b7 controlled safety stock<\/p>\n<h1>Reorder-Level Arithmetic Worksheet<\/h1>\n<p class=\"vbm232-lead\">Add a separately validated forecast of demand during replenishment lead time to a separately approved safety-stock quantity.<\/p>\n<div class=\"vbm232-badges\"><span class=\"vbm232-badge\">No invented safety stock<\/span><span class=\"vbm232-badge\">No automatic rounding<\/span><span class=\"vbm232-badge\">No order or criticality verdict<\/span><\/div>\n<\/header>\n<div class=\"vbm232-notice\"><strong>Arithmetic only\u2014not an inventory policy or purchase authorization.<\/strong> The worksheet does not forecast intermittent demand, estimate lead-time uncertainty, set a service level, determine a critical spare, calculate an order quantity, round to packs, value inventory or decide when a purchase order is released. Those decisions belong to the controlled continuous\/periodic-review policy and asset-risk process.<\/div>\n<form id=\"vbm232-form\" class=\"vbm232-card\" autocomplete=\"off\" novalidate>\n<h2>Controlled policy quantities<\/h2>\n<div class=\"vbm232-grid\">\n<div class=\"vbm232-field\"><label for=\"vbm232-demand\">Expected demand during replenishment lead time, E[DDL]<\/label><input id=\"vbm232-demand\" type=\"text\" inputmode=\"decimal\" placeholder=\"e.g. 6\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-safety\">Approved safety stock, SS<\/label><input id=\"vbm232-safety\" type=\"text\" inputmode=\"decimal\" placeholder=\"e.g. 2\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-unit\">Stocking unit \/ UOM<\/label><input id=\"vbm232-unit\" type=\"text\" placeholder=\"each, kg, L; required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-part\">Part \/ material \/ stock ID<\/label><input id=\"vbm232-part\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-policy\">Review policy and trigger definition<\/label><input id=\"vbm232-policy\" type=\"text\" placeholder=\"continuous\/periodic; required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-position\">Inventory-position definition<\/label><input id=\"vbm232-position\" type=\"text\" placeholder=\"on hand + on order \u2212 backorders...; required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-history\">Demand\/failure history source and window<\/label><input id=\"vbm232-history\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-model\">Demand model and E[DDL] derivation<\/label><input id=\"vbm232-model\" type=\"text\" placeholder=\"intermittent\/Poisson\/empirical\/etc.; required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-lead\">Lead-time definition, data and variability<\/label><input id=\"vbm232-lead\" type=\"text\" placeholder=\"order release through usable receipt; required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-service\">Safety-stock method and service objective<\/label><input id=\"vbm232-service\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-risk\">Asset criticality, credible failures and outage consequence<\/label><input id=\"vbm232-risk\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-supply\">Supplier, repair, substitution and redundancy record<\/label><input id=\"vbm232-supply\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-life\">Shelf life, preservation, obsolescence and interchangeability<\/label><input id=\"vbm232-life\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-order\">Order quantity, pack size and minimum-order policy<\/label><input id=\"vbm232-order\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-cost\">Controlled holding\/stockout\/procurement cost source<\/label><input id=\"vbm232-cost\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-source\">Policy\/model source, revision and approval<\/label><input id=\"vbm232-source\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-person\">Owner \/ reviewer<\/label><input id=\"vbm232-person\" type=\"text\" placeholder=\"required\"><\/div>\n<div class=\"vbm232-field\"><label for=\"vbm232-date\">Review date<\/label><input id=\"vbm232-date\" type=\"text\" placeholder=\"YYYY-MM-DD\"><\/div>\n<div class=\"vbm232-field full\"><label for=\"vbm232-notes\">Notes and exclusions <span class=\"vbm232-hint\">Optional: seasonal demand, common-mode failure, repair loop, cannibalization, staged location, quality\/traceability, open purchase orders<\/span><\/label><textarea id=\"vbm232-notes\"><\/textarea><\/div>\n<\/p><\/div>\n<div class=\"vbm232-checks\">\n   <label class=\"vbm232-check\"><input type=\"checkbox\" id=\"vbm232-c1\"><span>E[DDL] is the expected demand over the complete, consistently defined replenishment lead time. It is not an unverified average-rate \u00d7 average-time shortcut when demand\/lead time are dependent or variable.<\/span><\/label><br \/>\n   <label class=\"vbm232-check\"><input type=\"checkbox\" id=\"vbm232-c2\"><span>SS comes from the approved demand\/lead-time distribution, service objective and consequence model\u2014not the former generic \u201c1\u20133 units,\u201d maximum-demand shortcut or a copied Z\u03c3\u221aLT expression outside its assumptions.<\/span><\/label><br \/>\n   <label class=\"vbm232-check\"><input type=\"checkbox\" id=\"vbm232-c3\"><span>The trigger is applied to the controlled inventory position and review policy, including on-order\/backorder\/reservation rules; this result is not automatically rounded or converted to an order quantity.<\/span><\/label><br \/>\n   <label class=\"vbm232-check\"><input type=\"checkbox\" id=\"vbm232-c4\"><span>For critical spares, asset function, credible failures, monitoring warning, repair\/substitution\/redundancy, supplier risk, preservation, obsolescence and quality traceability are reviewed separately.<\/span><\/label>\n  <\/div>\n<div class=\"vbm232-actions\"><button type=\"submit\" class=\"vbm232-primary\">Add controlled quantities<\/button><button type=\"button\" class=\"vbm232-secondary\" id=\"vbm232-clear\">Clear<\/button><\/div>\n<div id=\"vbm232-error\" class=\"vbm232-error\" role=\"alert\"><\/div>\n<\/p><\/form>\n<section id=\"vbm232-results\" class=\"vbm232-card vbm232-results\" aria-live=\"polite\">\n<h2>Documented arithmetic<\/h2>\n<div class=\"vbm232-result-grid\">\n<div class=\"vbm232-result primary\">\n<div class=\"vbm232-result-label\">Unrounded reorder level R<\/div>\n<div class=\"vbm232-result-value\" id=\"vbm232-r-level\">\u2014<\/div>\n<\/div>\n<div class=\"vbm232-result\">\n<div class=\"vbm232-result-label\">Expected lead-time demand<\/div>\n<div class=\"vbm232-result-value\" id=\"vbm232-r-demand\">\u2014<\/div>\n<\/div>\n<div class=\"vbm232-result\">\n<div class=\"vbm232-result-label\">Approved safety stock<\/div>\n<div class=\"vbm232-result-value\" id=\"vbm232-r-safety\">\u2014<\/div>\n<\/div><\/div>\n<div class=\"vbm232-status\" id=\"vbm232-r-status\"><\/div>\n<\/section>\n<section class=\"vbm232-card\">\n<h2>Equation and classification<\/h2>\n<div class=\"vbm232-formula\">R = E[DDL] + SS<\/div>\n<p>R is the unrounded reorder level in the same stocking unit; E[DDL] is expected demand during replenishment lead time; SS is the approved safety stock. MIT OpenCourseWare states this continuous-review identity as \u201cROP = expected demand during order lead time + safety stock.\u201d It is a <strong>general inventory-policy relation, not an ISO formula<\/strong>. How E[DDL] and SS are estimated\u2014and whether\/when inventory position triggers an order\u2014depends on the controlled policy.<\/p>\n<\/section>\n<section class=\"vbm232-card\">\n<h2>Model boundary and removed unsupported content<\/h2>\n<ul>\n<li><strong>No automatic d \u00d7 LT model.<\/strong> Multiplying average demand rate by average lead time requires consistent units and assumptions; variable\/dependent demand and lead time require the validated lead-time-demand model. The worksheet accepts controlled E[DDL] directly.<\/li>\n<li><strong>No universal safety-stock formula.<\/strong> Z\u03c3\u221aLT is only one special case with specific distribution, independence, period and lead-time assumptions. \u201cTypically 1\u20133 units,\u201d \u201cuse maximum demand,\u201d and \u201cone spare after six months\u201d were unsourced universal advice.<\/li>\n<li><strong>No automatic ceiling.<\/strong> Indivisibility, pack size, minimum order, review cadence and order quantity belong to the policy. The former Math.ceil silently changed the mathematical R.<\/li>\n<li><strong>No fake inventory value.<\/strong> R \u00d7 unit purchase price is not automatically inventory value or carrying cost; valuation basis, on-order\/backorders, quantities, currency, preservation, obsolescence and accounting policy were absent.<\/li>\n<li><strong>No fixed 20\u201325% holding cost.<\/strong> OpenStax identifies storage, insurance, obsolescence\/spoilage and opportunity cost components but supplies no universal percentage for this spare-parts context.<\/li>\n<li><strong>No critical-spare verdict.<\/strong> DOE audits show that critical-spare programs must establish parts, sparing levels\/reorder points and strategic staging, and define credible failures\/advance warning; this two-number sum cannot perform that risk assessment.<\/li>\n<\/ul>\n<\/section>\n<section class=\"vbm232-card\">\n<h2>Source traceability<\/h2>\n<table>\n<thead>\n<tr>\n<th>Claim<\/th>\n<th>Classification<\/th>\n<th>Evidence<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>ROP = E{demand during lead time} + safety stock; E[DDL] may need demand and lead-time variability terms.<\/td>\n<td>Official university course material<\/td>\n<td><a href=\"https:\/\/ocw.mit.edu\/courses\/15-760a-operations-management-spring-2002\/3a2597887c580db1a7807bd1731b7280_lecture18_mar18.pdf\" target=\"_blank\" rel=\"noopener\">MIT OCW 15.760A, Lecture 18<\/a><\/td>\n<\/tr>\n<tr>\n<td>WAPA audit findings included failure to demonstrate identified critical parts, sparing levels, reorder points and strategic locations; critical spares relate to credible failures and procurement warning.<\/td>\n<td>Official US DOE audit evidence<\/td>\n<td><a href=\"https:\/\/www.energy.gov\/ig\/articles\/audit-doe-oig-24-30\" target=\"_blank\" rel=\"noopener\">DOE-OIG-24-30, 27 Sep 2024<\/a><\/td>\n<\/tr>\n<tr>\n<td>Spare-parts ordering should use component failure history within an O&amp;M program and preserve equipment\/supplier records.<\/td>\n<td>Official US DOE guidance<\/td>\n<td><a href=\"https:\/\/www.energy.gov\/cmei\/femp\/optimizing-solar-photovoltaic-performance-longevity\" target=\"_blank\" rel=\"noopener\">DOE FEMP O&amp;M guidance<\/a><\/td>\n<\/tr>\n<tr>\n<td>Holding costs include storage, insurance, obsolescence\/spoilage and opportunity cost; ordering and stockout costs are separate.<\/td>\n<td>Open peer-reviewed university textbook<\/td>\n<td><a href=\"https:\/\/openstax.org\/books\/principles-finance\/pages\/19-5-inventory-management\" target=\"_blank\" rel=\"noopener\">OpenStax Principles of Finance \u00a719.5<\/a><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"vbm232-small\"><strong>Accessed:<\/strong> 15 July 2026. None of these sources establishes a universal safety stock, holding-cost percentage, pack rounding or purchase authorization for the entered part.<\/p>\n<\/section>\n<section class=\"vbm232-card\">\n<h2>Arithmetic reference example<\/h2>\n<p>If a validated model gives E[DDL] = 6.25 each and the approved safety stock is 2.5 each, R = 8.75 each. The worksheet intentionally does not round 8.75, decide the trigger condition or calculate the order quantity.<\/p>\n<\/section>\n<section class=\"vbm232-card\">\n<h2>Questions<\/h2>\n<details>\n<summary>Why not enter monthly demand and lead-time months?<\/summary>\n<p>That multiplication is safe only under the validated demand\/lead-time assumptions. Entering E[DDL] directly keeps the forecast model and its uncertainty visible.<\/p>\n<\/details>\n<details>\n<summary>Should the result be rounded up?<\/summary>\n<p>Only the controlled unit, pack, order-quantity and review policy can decide rounding. The arithmetic relation itself does not.<\/p>\n<\/details>\n<details>\n<summary>Does this set the stock for a critical spare?<\/summary>\n<p>No. Criticality, credible failure modes, warning time, repair and substitution options, redundancy, supplier risk, staging, preservation and obsolescence must be assessed separately.<\/p>\n<\/details>\n<\/section>\n<p><\/main><br \/>\n<script>\n(function(){'use strict';var form=document.getElementById('vbm232-form'),error=document.getElementById('vbm232-error'),results=document.getElementById('vbm232-results');\nfunction parseDecimal(value,label){var s=String(value==null?'':value).trim();if(!\/^[+]?(?:\\d+(?:[.,]\\d*)?|[.,]\\d+)$\/.test(s))throw new Error(label+' must be one nonnegative plain decimal using a point or comma.');var n=Number(s.replace(',','.'));if(!Number.isFinite(n))throw new Error(label+' is outside the finite numeric range.');return n}\nfunction requiredText(id,label){var value=document.getElementById(id).value.trim();if(!value)throw new Error(label+' is required.');return value}\nfunction calculate(values){var demand=parseDecimal(values.demand,'Expected lead-time demand'),safety=parseDecimal(values.safety,'Approved safety stock'),level=demand+safety;if(![demand,safety,level].every(Number.isFinite))throw new Error('The reorder-level result is outside the finite numeric range.');return{demand:demand,safety:safety,level:level}}\nfunction fmt(n){if(!Number.isFinite(n))return'\u2014';if(n===0)return'0';return(n>=1e9||n<1e-6?n.toExponential(9):n.toPrecision(10)).replace(\/(\\.\\d*?[1-9])0+(e|$)\/,'$1$2').replace(\/\\.0+(e|$)\/,'$1')}\nfunction setText(id,text){document.getElementById(id).textContent=text}function render(r){var unit=requiredText('vbm232-unit','Stocking unit \/ UOM');setText('vbm232-r-level',fmt(r.level)+' '+unit);setText('vbm232-r-demand',fmt(r.demand)+' '+unit);setText('vbm232-r-safety',fmt(r.safety)+' '+unit);setText('vbm232-r-status','Unrounded addition only. 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