Methodology for integrated inventory optimisation in production and trading enterprises: A systematic review and meta-analytic synthesis
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inventory optimisation, safety stock calibration, multi-echelon inventory, deep reinforcement learning, ABC-XYZ segmentation, demand forecasting, digital twin
Abstract
Purpose. This study aims to synthesise empirical and modelling evidence on inventory optimisation methods for raw materials, work-in-process, and finished goods in production and trading enterprises, and to translate that evidence into a practical, class-differentiated implementation framework deployable within standard warehouse management and enterprise resource planning systems. Methodology. A systematic review and meta-analytic synthesis of 31 peer-reviewed studies published between 2004 and 2025 was conducted following the PRISMA 2020 protocol. A random-effects model estimated by restricted maximum likelihood was applied to pool percentage cost-reduction effect sizes across 18 studies admissible to quantitative synthesis, complemented by a narrative synthesis of the remaining 13 studies. Pre-specified subgroup and moderator analyses examined the role of inventory class, demand pattern, and network complexity as effect-size moderators. Results. Distributional safety stock methods outperform classical normal approximations by a pooled mean of 9.3% (95% CI: 5.8–12.7%) at equivalent service levels, with the advantage being largest for high-variability SKU segments. Multi-echelon coordination yields a pooled mean cost reduction of 11.4% (95% CI: 6.9–15.9%), increasing significantly with network complexity and lead-time variability. Learning-based control methods deliver up to 16% cost reductions under complex network conditions but require substantial data and governance infrastructure. Commercial demand drivers systematically distort finished-goods inventory targets and require integration with sales-and-operations planning for accurate calibration. Theoretical contribution. The study provides the first cross-class synthesis covering raw materials, work-in-process, and finished goods within a unified evaluative framework, positioning machine learning and deep reinforcement learning methods alongside classical policy families and quantifying the boundary conditions for each approach. Practical implications. A six-phase, stepwise implementation framework is proposed, covering ABC-XYZ segmentation, forecast model selection, safety stock calibration, replenishment policy assignment, simulation-based parameter tuning, and KPI governance, enabling enterprises to achieve 9–16% reductions in inventory costs within existing WMS and ERP architectures.
Sustainable Development Goals (SDGs): SDG 8: Decent Work and Economic Growth; SDG 9: Industry, Innovation and Infrastructure; SDG 12: Responsible Consumption and Production; SDG 17: Partnerships for the Goals
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Copyright (c) 2026 Tetiana Kashtalian
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