February 21, 2023
By:EmpoweringCPO Insights Team

Metrics for Spare Parts Inventory Management

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Background

The report helps in Metrics for Spare Parts Inventory Management (MRO) of spare parts in process industries. There are different models used for inventory analyses and demand forecasting. The report also gives insights into the challenges and best practices in spare part management.

Abstract

  • Leading manufacturing companies like PepsiCo, Coca-Cola, Nestlé, etc. deploy VMI (Vendor Managed Inventory) services from leading industrial supply companies and distributors for maintaining optimum spare parts inventory.
  • ABC (consumption), FSN (frequency), VED (criticality), SDE (lead time), and EOQ are widely used models for inventory analyses for process industries.
  • The life cycle of spare parts in any manufacturing industry:
    1. Spare Part Need Identification
    2. Request for Order
    3. Approval
    4. Procurement
    5. Delivery, Receiving
    6. Warehousing
    7. Consumption
    8. Back Flow
  • Several Process Bottlenecks arise throughout the life cycle from RFO approval to Warehouse returns.
  • The challenges faced by spare parts management are Monitoring overall performance, Making informed decisions for planning & budgeting, Getting inventory visibility for better control, etc.
  • The best practices in spare parts management include:
    1. Multi-model-based inventory management
    2. Optimization models for multi-echelon inventory, Capabilities for operational as well as tactical planning,
    3. Forecasting algorithms,
    4. Ability to handle part alternates and substitution, etc.
  • The demand forecasting for spare parts can be done by using the Constant model, Regression model, Holt’s exponential smoothing, Simple exponential smoothing, Moving average (ARIMA) & Winter method.
  • The spare parts strategy goal can be achieved by utilizing efficient CMMS (Computerized maintenance management system/ software), Data Analytics, and Reporting.

 

Table of Content

ContentsSlide No.
Industry Trends3
KPIs for MRO – Quantitative and Qualitative4
Life Cycle of a Spare Part5
Eliminating Process Bottlenecks6
Spare Part Management Challenges7
Efficient Spare Parts Management – 8 Rules8
Best Practices in Spare Parts Management9, 10
Majorly Used Inventory Analyses11
Models Used for Demand Forecasting12
Spare Part Strategy – Cost Vs Stock Level13
Spare Parts Management – Objectives & Solutions14

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Compliance management is very critical as otherwise the procurement organization may run into a scenario where there is a huge gap between realized savings and reported savings. Many procurement functions estimate large savings numbers when contracts are signed. They also invest significant time and effort in negotiating contracts for necessary goods and services, only to have a third or more of their purchasing dollars flow outside those deals. Some of the obvious fall-outs of non-compliance and maverick purchases are:

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