Many organizations rely on internal historical data to drive demand planning and forecasting in today's dynamic world. While this process acted as a rich source of insights, its ability to create accurate forecasts degraded significantly during the pandemic. It had frequent demand anomalies making it difficult for supply chain managers to predict and act in real-time. They often had to manually realign strategies with external market conditions and find ways to meet customer demands. However, with supply chain 4.0 – the next generation digital supply chain, organizations are taking an opportunity to make demand forecasting more dynamic and resilient.

Traditional forecasting was based mostly on historical data residing in the enterprise systems and the manager's knowledge of external data. Demand planners made manual corrections to forecasts based on market inputs related to external data (Market trends, Weather, Local events, etc.). Often the process created a huge lag with forecast accuracy.

While the forecast worked to a degree at the aggregate level, they had huge errors that were hard to explain at the SKU level. The statics from CFO research services in Fig 1 provides an independent view of how external factors influence forecast errors and inventory

Forecasting is mostly a monthly process, and any major deviations within the month have been a challenge both from process and systems. Demand and Inventory managers have to make complex and costly inventory decisions based on forecasts that could be inaccurate. The loop between demand planning and supply planning is often broken, making supply chain managers' role in their ability to make supply chain trade-off decisions complex and tedious.

Very few organizations today have clear and robust capabilities to co-relate external variables' impact on their forecasts

As industries move towards Industry 4.0, the volume, velocity, and variety, value, and veracity of supply chain data become all the more significant for increased supply chain risks. One of the key hedges to prevent a digital disruption is to have a world-class forecasting process that is intelligent, dynamic, and constantly adapting to changing markets. Customer expectations in the digital world are dynamic, with expectations in the digital world are dynamic with expectations of highly individualized products driving a trend towards mass customization. Forecasts in the digital supply chain need to be more granular segmented at a customer level, allowing them to choose ‘exactly’ what fits their needs. Forecasts need to be carried out dynamically on multiple time frames, i.e., monthly, weekly, or even daily, based on the product velocity. Inventory levels need to be adjusted accordingly in a digital supply chain to ensure the right product is at the right place at the right time in the right quantities.