Cost effective supply chain management under various market, logistics and production uncertainties is a critical issue for companies in the chemical process industry. Uncertainties in the supply chain usually increase the variance of profits (or costs) to the company, increasing the likelihood of decreased profit. Demand uncertainty, in particular, is an important factor to be considered in the supply chain design and operations. To hedge against demand uncertainty, safety stock levels are commonly introduced in supply chain operations as well as in supply chain design. Although there exists a large body of literature on estimating safety stock levels based on traditional inventory theory, this literature does not provide an effective methodology that can address the complexity of real CPI supply chains and that can impact the current practice in their design, planning and scheduling. In this paper, we propose the use of deterministic planning and scheduling models which incorporate safety stock levels as a means of accommodating demand uncertainties in routine operation. The problem of determining the safety stock level to use to meet a desired level of customer satisfaction is addressed using a simulation based optimization approach. An industrial-scale case problem is presented to demonstrate the utility of the proposed approach. (C) 2004 Elsevier Ltd. All rights reserved.