Reorder Point Definition, Formula, How to Calculate?



Companies that operate ‘just in time’ or ‘Lean inventory management’ will often adopt this shortened formula. The average lead time in days is how long it takes for your raw materials to be delivered from a supplier or how long it takes you to manufacture a product. The delivery time and manufacturing rate are also part of understanding your manufacturing lead time. As the above graph visualizes, lead time represents the amount of time it takes for items to become available from the moment they are ordered. It is thus an instrumental part of the ROP calculation and helps to avoid inventory levels falling below the safety stock line.

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The reorder point is the minimum number of units that a business needs to have in stock to prevent stock outs and ensure order fulfillment. Once inventory levels reach the reorder point, this triggers the replenishment process to reorder that item. The ultimate goal of reorder point is to maintain an amount of inventory at a level that can always meet customer demand without having more than is realistically possible to move.

What is Safety Stock

Unnecessary expenditure in stocking and maintaining the inventory is reduced. It makes space to identify procurement issues and helps resolve them, leading to a smoother process. To produce one doll, the company requires one pack of wooden pieces.

What is a reorder level example?

Example of the Reorder Level Formula

For example, Wilberforce Products experiences average daily usage of its black widget of 100 units, and the lead time for procuring new units is eight days. Thus, the reorder level is 100 units x 8 days = 800 units.

It might seem like a lot for a that only moves four units a day, but in this case it’s the long lead time that drives the result. When inventory reaches the level specified by the ROP, that means it’s time to act. Reorder points simplify and streamline the business decision of when to reorder inventory. So when the stock levels hit 2000 a reorder alert will be triggered. Using reorder points allows businesses to have less stock on hand . This makes it less likely that you will have unused inventory costing sitting in your warehouse costing you money. Basically, you just have to understand the item like if it was an item in your kitchen or ask your purchasers what they actually do.

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He has a highly informative writing style that does not sacrifice readability. Working closely with manufacturers on case studies and peering deeply into a plethora of manufacturing topics, Mattias always makes sure his writing is insightful and well-informed.

Reorder Pointd success and sales demand do not have to become a burden. Katana automatically flags the product and material variants that have dipped below their reorder point, allowing you to identify the areas that require action. If you don’t, your safety stock will eventually deplete to nothing, and since more orders cost more money, you should try to avoid this. This means your stock will be regulated much better, with fewer interruptions like supply chain breakdowns or production bottlenecks. The move ensured that none of the essential supplies would ever be out of stock while still significantly reducing their inventory and freeing up capital.

Calculating Reorder Points Are An Inventory Management Best Practice

With all that and plenty more, trying to maintain independent inventory levels for an entire store can easily be overlooked or placed on the “oh I’ll get to that tomorrow when I have more time” list. The reorder point model works best with retailers that have available information on their point of sale system. This model was initially created for large companies to manage inventory but the same principals can be applied to small retail locations as well. Trying to run a small business is a tricky task that requires owners to be a jack-of-all-trades. On any given day you could be updating a balance sheet, working on advertising, interacting with customers, and constructing employee schedules for the coming weeks.


This amount indicates how much of the item your business is likely to consume during the lead time. Adding safety stock to this figure gives that extra measure of caution in case demand increases or something unexpected causes lead time to extend beyond the maximum. This means you can better plan for potential demand spikes and stockouts, as well as keep storage costs low and your bottom line happy. Doing a stock count will be much easier if you continually keep an eye on your inventory levels. By that, I mean all year round, not only during your stock count day. If mistakes were made several weeks before your stocktake, it’d be too difficult to tidy things up by the time you discover them. Finally, safety stock is how many units of extra inventory you want to keep on hand just in case there are shipping delays or your daily sales rate unexpectedly goes up.

Reorder faster with inFlow

Conversely, if managing your on-site inventory is becoming difficult or costly due to how much you have, and you’re not reordering very often at all, you may have set the quantity too high. Reorder points are about timing, not quantity, but that doesn’t mean quantity isn’t important. If you’re struggling with order quantity, economic order quantity calculations, which are designed to find a given business’s optimal order quantity, may be useful.

  • Integrating reorder points and safety stock into your replenishment calculations is essential.
  • So, producing too many finished goods could end up evaporating your profit margin.
  • When you reach the reorder point, Extensiv Order Manager automatically creates a PO with a recommended quantity to reorder.
  • By thinking about your business logistics, you can ensure that it operates at its optimum level.
  • It also factors in goods in transit , which are products that have been ordered from a vendor but haven’t been received yet.

Rich inventory insights like these empower businesses to fine-tune their reorder points and overall inventory management processes. A modern inventory management system can bring greater efficiency to inventory processes through automation and digital tools. For example, real-time inventory tracking allows staff to see what’s in stock, what’s on order, and where each item is located.

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