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REDUCE MRO SPARES BY 10% WITH “WHERE USED” REPORTS


THE COST OF MRO SPARES

MRO Spares are spare parts used by maintenance teams to repair broken
equipment.  By holding onto spare parts for critical assets, they are able to
drastically reduce the downtime of equipment, by immediately starting repairs
and not waiting for new parts to be shipped.

This process, however, comes at a cost.   Insurance premiums often run at 5% of
total inventory value, and taking into account embedded costs like salaries and
wages, buildings and utilities to manage the spare parts inventory, the total
administrative exposure for carrying cost can add up to as much as 20% or
more.   These are not one-and-done expenses; they occur every year, year after
year, for as long as you carry storeroom inventory for an asset.


A REASON WHY SUPERFLUOUS SPARES EXIST

Most leading ERP solutions have modules or customizations that address MRO
inventory procurement and inventory management. However, there are various holes
in their systems that leave businesses at a difficult crossroads: Do you invest
the resources needed to identify unnecessary MRO Spares or do you absorb the
cost of these Spares and invest resources elsewhere?

For example, a client of ours recently came to us with this issue.  They had
just decommissioned an old machine which was backfilled by a substantial amount
of MRO Spares in their warehouse.  They were unable to sell or remove the spares
used for this machine because some parts were also used by other critical assets
– they just didn’t know which ones.  After hiring an SAP Analyst, they learned
how rigorous the process of identifying which parts were used on other
machines.  The Analyst had to either go through every work order to track down
parts or create a custom “Where Used” script in SAP for every part on the
machine.


THE CURE FOR SPARES ABUNDANCE

Asset Information Center (AIC) knows every part used in every machine, and
correlates that information with the Bill of Materials.  This allows businesses
to see where any part is being used with the click of a button and, in turn,
quickly identify their useful or unnecessary spares.

Our client, who initially used AIC to quickly find parts needed for repairs and
optimize their work order process, was able to use this additional feature to
reduce their total MRO Spares by 10%.  Not only did it work for the asset they
had just decommissioned, but they were able to do this retroactively with other
legacy equipment.  They found thousands of spares in their warehouse and were
able to re-sell them; turning a potential loss into profit.

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