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Control charts are designed to be effective in detecting a shift in the distribution of a process. Typically, these charts assume that the data for these processes follow an approximately normal distribution or some known distribution. However, if a data-generating process has a large proportion of zeros, that is, the data is intermittent, then traditional control charts may not adequately monitor these processes. The purpose of this study is to examine proposed control chart methods designed for monitoring a process with intermittent data to determine if they have a sufficiently small percentage of false out-of-control signals. Forecasting techniques for slow-moving/intermittent product demand have been extensively explored as intermittent data is common to operational management applications (Syntetos & Boylan, 2001, 2005, 2011; Willemain, Smart, & Schwarz, 2004). Extensions and modifications of traditional forecasting models have been proposed to model intermittent or slow-moving demand, including the associated trends, correlated demand, seasonality and other characteristics (Altay, Litteral, & Rudisill, 2012). Croston’s (1972) method and its adaptations have been among the principal procedures used in these applications. This paper proposes adapting Croston’s methodology to design control charts, similar to Exponentially Weighted Moving Average (EWMA) control charts, to be effective in monitoring processes with intermittent data. A simulation study is conducted to assess the performance of these proposed control charts by evaluating their Average Run Lengths (ARLs), or equivalently, their percent of false positive signals.

One aspect of forecasting intermittent demand for slow-moving inventory that has not been investigated to any depth in the literature is seasonality. This is due in part to the reliability of computed seasonal indexes when many of the periods have zero demand. This chapter proposes an innovative approach which adapts Croston's (1970) method to data with a multiplicative seasonal component. Adaptations of Croston's (1970) method are popular in the literature. This method is one of the most popular techniques to forecast items with intermittent demand. A simulation is conducted to examine the effectiveness of the proposed technique extending Croston's (1970) method to incorporate seasonality.

A Bayesian approach to demand forecasting to optimize spare parts inventory that requires periodic replenishment is examined relative to a non-Bayesian approach when the demand rate is unknown. That is, optimal inventory levels are decided using these two approaches at consecutive time intervals. Simulations were conducted to compare the total inventory cost using a Bayesian approach and a non-Bayesian approach to a theoretical minimum cost over a variety of demand rate conditions including the challenging slow moving or intermittent type of spare parts. Although Bayesian approaches are often recommended, this study’s results reveal that under conditions of large variability across the demand rates of spare parts, the inventory cost using the Bayes model was not superior to that using the non-Bayesian approach. For spare parts with homogeneous demand rates, the inventory cost using the Bayes model for forecasting was generally lower than that of the non-Bayesian model. Practitioners may still opt to use the non-Bayesian model since a prior distribution for the demand does not need to be identified.

Research in the area of forecasting and stock inventory control for intermittent demand is designed to provide robust models for the underlying demand which appears at random, with some time periods having no demand at all. Croston’s method is a popular technique for these models and it uses two single exponential smoothing (SES) models which involve smoothing constants. A key issue is the choice of the values due to the sensitivity of the forecasts to changes in demand. Suggested selections of the smoothing constants include values between 0.1 and 0.3. Since an ARIMA model has been illustrated to be equivalent to SES, an optimal smoothing constant can be selected from the ARIMA model for SES. This chapter will conduct simulations to investigate whether using an optimal smoothing constant versus the suggested smoothing constant is important. Since SES is designed to be an adapted method, data are simulated which vary between slow and fast demand.

When forecasting intermittent demand the method derived by Croston (1972) is often cited. Previous research favorably compared Croston's forecasting method for demand with simple exponential smoothing assuming a nonzero demand occurs as a Bernoulli process with a constant probability. In practice, however, the assumption of a constant probability for the occurrence of nonzero demand is often violated. This research investigates Croston's method under violation of the assumption of a constant probability of nonzero demand. In a simulation study, forecasts derived using single exponential smoothing (SES) are compared to forecasts using a modification of Croston's method utilizing double exponential smoothing to forecast the time between nonzero demands assuming a normal distribution for demand size with different standard deviation levels. This methodology may be applicable to forecasting intermittent demand at the beginning or end of a product's life cycle.