TL;DR: HML analysis helps manufacturers prioritize inventory based on unit cost, so high-value items get tighter control while low-value items are managed with simpler rules.

As a manufacturing business, there are several ways to manage inventory better. Each method serves a different purpose. HML analysis in inventory management is one such method that focuses specifically on the unit value of items.

What Is HML Inventory Analysis?

HML analysis in inventory management is a method used to classify inventory items based on their unit cost. Items are grouped into High, Medium, and Low categories depending on how expensive they are per unit.

The idea is simple: a small number of items usually account for a large share of inventory value. By identifying these items, manufacturers can focus control efforts where the financial risk is highest and avoid both overstocking and stockouts.

How To Do HML Inventory Analysis

HML inventory analysis follows a structured but straightforward process:

- List all inventory items along with their unit costs.

- Arrange items in descending order based on unit cost.

- Calculate annual consumption value using unit cost and annual demand.

- Define cutoff points to split items into High, Medium, and Low categories.

- Classify the most expensive items as High, mid-range items as Medium, and the cheapest items as Low.

- Review the classification regularly to maintain inventory accuracy.

Benefits Of HML Analysis In Inventory Management

Improved Inventory Control

HML analysis helps identify high-value items that need strict monitoring. This reduces the risk of production delays caused by stockouts while also preventing excess capital from being tied up in overstock.

Better Resource Utilization

By focusing time, money, and planning effort on high-value items, manufacturers can allocate resources where they have the biggest impact on costs and operational efficiency.

Smarter Purchasing Decisions

HML analysis supports informed purchasing by highlighting which items contribute most to inventory value. This allows better reorder planning and supplier management for critical items.

More Controlled Supply Chain

Classifying items into HML categories improves visibility across the supply chain. Medium and low-value items can be handled with simpler controls, while high-value items receive closer attention.

Higher Customer Satisfaction

Well-managed inventory leads to smoother production and on-time order fulfilment. This directly improves reliability and customer confidence.

Applications Of HML Analysis In Inventory Control

Optimizing Inventory Levels

HML analysis helps maintain optimal stock levels for expensive items, ensuring production continuity without excessive holding costs.

Improving Purchasing Strategy

Manufacturers can diversify suppliers for high-value items and maintain backups, reducing operational risk.

Integrating With ERP And Inventory Systems

HML analysis can be automated within ERP and inventory management systems, improving coordination between inventory, production, and finance teams.

How To Implement HML Analysis In Practice

• Gather accurate data on unit cost, demand, and usage.

• Sort items by unit cost in descending order.

• Calculate cumulative costs to understand value concentration.

• Define clear thresholds for High, Medium, and Low categories.

• Use charts or dashboards to review and act on HML insights.

FAQs

What is HML analysis in inventory management?

HML analysis is a method of classifying inventory into High, Medium, and Low categories based on unit cost.

How is HML analysis different from ABC analysis?

ABC analysis focuses on annual consumption value, while HML analysis focuses only on unit cost.

When should manufacturers use HML analysis?

HML analysis is useful when unit cost varies significantly across items and high-value materials require tighter control.

Can HML analysis be combined with other inventory methods?

Yes, HML analysis is often combined with ABC, VED, or FSN analysis for more balanced inventory decisions.

Is HML analysis suitable for Indian SME manufacturers?

Yes, it is especially useful for SMEs that need simple, cost-focused inventory controls without complex calculations.