NTEGRATED INVENTORY MANAGEMENT FOR MAINTENANCE, REPAIR & OPERATIONS (MRO) MATERIALS
“Optimizing Inventory, Service Levels, and Cost for Critical MRO Operations”
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 30 – 31 Jan 2025 | Kuala Lumpur, Malaysia | USD 1995 per delegate |
Course Introduction
Maintenance, Repair & Operations (MRO) materials are essential for ensuring equipment uptime, operational reliability, and plant safety. Yet MRO inventory is often overlooked, under-managed, or excessively stocked—leading to increased costs, stockouts, and operational delays.
This focused 2-day course helps maintenance, supply chain, and inventory professionals implement best practices for managing MRO materials. Participants will learn how to integrate maintenance strategies with inventory control systems, improve spare parts availability, reduce excess and obsolete inventory, and align procurement with operational need.
Course Objectives
By the end of this course, participants will be able to:
- Understand the unique challenges and cost dynamics of MRO materials.
- Align MRO inventory policies with maintenance strategies (PM, Pd.M., RCM).
- Improve spare parts classification, stocking decisions, and reorder practices.
- Eliminate obsolete and redundant items through structured data and analysis.
- Build integration between maintenance, procurement, and warehouse functions.
- Apply KPIs and dashboards to monitor MRO inventory performance.
Key Benefits of Attending
- Avoid costly downtime due to missing critical spares.
- Reduce excess and slow-moving inventory in storerooms.
- Learn how to clean and structure MRO data for effective control.
- Implement a governance model for spare parts ownership and usage.
- Improve visibility and collaboration across departments.
Intended Audience
This program is designed for:
- Inventory and materials management professionals
- Maintenance and reliability engineers
- Maintenance planners and warehouse supervisors
- Procurement and supply chain teams supporting MRO
- Plant managers and operations leaders
Individual Benefits
Key competencies that will be developed include:
- Inventory classification and master data cleanup
- MRO inventory costing and stock level optimization
- Spare parts demand forecasting
- Cross-functional MRO collaboration
- CMMS/ERP usage for MRO integration
Organization Benefits
Upon completing the training course, participants will demonstrate:
- Higher availability of critical spares with lower inventory cost
- Improved collaboration between stores, maintenance, and procurement
- Better visibility of inventory health and lifecycle
- More efficient planning of shutdowns and maintenance execution
- Enhanced spare parts traceability and standardization
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
- Expert-led technical briefings
- MRO performance templates and decision matrices
- Real-world case studies and industry benchmarking
- Practical group exercises and scenario planning
- Workshop simulations for stock optimization
Course Outline
Detailed 2-Day Course Outline
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: MRO Strategy, Classification & Control
Module 1: Introduction to MRO Inventory Management (07:30 – 09:30)
- What makes MRO unique from production inventory
- MRO demand characteristics and service level targets
- Impact of poor MRO control on operations
Module 2: Inventory Classification and Data Cleansing (09:45 – 11:15)
- ABC/VED/FSN/XYZ classification for MRO
- Bill of Materials (BoM) and criticality ratings
- Master data cleanup and duplication elimination
Module 3: Maintenance Strategy Alignment (11:30 – 01:00)
- PM, Pd.M., RCM and their impact on spare parts planning
- Linking CMMS/ERP with inventory systems
- Building cross-functional decision-making processes
Module 4: Workshop – Critical Spares Classification Simulation (02:00 – 03:30)
- Participants analyze real-world examples to classify inventory and determine stocking policies
Day 2: Planning, Optimization & Integration
Module 5: Stocking Policies and Reorder Parameters (07:30 – 09:30)
- Reorder point vs. Min/Max strategies
- Lead time analysis and safety stock settings
- Service levels, availability metrics, and economic order quantities (EOQ)
Module 6: Obsolescence, Surplus, and Rationalization (09:45 – 11:15)
- Strategies to manage and reduce excess inventory
- Aging and disposal policies
- Root causes of MRO overstock and duplication
Module 7: Governance, KPIs, and Stakeholder Integration (11:30 – 01:00)
- Metrics for inventory health, value, and turns
- Defining roles and ownership (maintenance vs. procurement vs. stores)
- Building accountability and communication channels
Module 8: Final Simulation – Inventory Improvement Plan (02:00 – 03:30)
- Teams develop a basic action plan for MRO inventory optimization and stakeholder alignment
Certification
Participants will receive a Certificate of Completion in Integrated Inventory Management for MRO Materials, validating their ability to manage, control, and optimize MRO inventory systems for operational excellence.