WAREHOUSE OPERATIONS & SPARE PARTS INVENTORY CONTROL & OPTIMIZATION
Master the Operational and Strategic Practices for Efficient Spare Parts Warehousing and Inventory Performance
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Course Schedule
| Date | Venue | Fees (Face-to-Face / Online) |
|---|---|---|
| 10 – 14 Feb 2025 | Dubai, UAE | USD 3495 per delegate |
| 13 – 17 Apr 2025 | Doha, Qatar | USD 3495 per delegate |
| 11 – 15 May 2025 | Kuwait | USD 3495 per delegate |
| 11 – 15 Aug 2025 | London, UK | USD 3495 per delegate |
| 02 – 06 Mar 2025 | Manama, Bahrain (Online) | USD 1500 per delegate |
| 26 – 30 Oct 2025 | Manama, Bahrain | USD 3495 per delegate |
Course Introduction
Spare parts management is one of the most complex areas of inventory and warehouse operations, often involving high-value, low-turnover items critical for maintenance and uptime. Inefficient practices can lead to part obsolescence, overstocking, high holding costs, and equipment downtime.
This 5-day practical course is designed to help warehouse and inventory professionals develop the skills to optimize spare parts storage, improve retrieval efficiency, and apply best practices in demand forecasting, classification, and lifecycle control. Participants will learn to streamline warehouse layouts, reduce slow-moving stock, and implement controls tailored to spare parts management challenges.
Course Objectives
By the end of this course, participants will be able to:
• Understand the unique characteristics and challenges of spare parts inventory
• Plan and manage effective warehouse layouts for parts of varied size and value
• Apply ABC, FSN, and criticality analysis to classify spare parts
• Implement cycle counting, stock audits, and aging inventory controls
• Develop replenishment models that align with maintenance schedules
• Improve service levels and reduce stockouts without over-investing in inventory
Key Benefits of Attending
• Learn industry best practices for organizing and controlling spare parts inventory
• Optimize space, cost, and service in technical stores and maintenance warehouses
• Improve accuracy, traceability, and issue-return processes
• Prevent losses due to aging, obsolescence, and misclassification
• Gain practical tools to support warehouse audits and spare parts optimization
Intended Audience
This program is designed for:
• Warehouse and store managers
• Inventory and materials control staff
• Maintenance and spare parts planners
• Technical storekeepers and logistics professionals
• Engineers and maintenance personnel responsible for MRO inventory
Individual Benefits
Key competencies that will be developed include:
• Classification and optimization of slow-moving and critical parts
• Inventory recording, tracking, and auditing
• Effective warehouse layout planning for parts storage
• Lifecycle analysis and obsolescence prevention
• Improved spare parts request, issue, and return processing
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Improved warehouse productivity and space utilization
• Lower inventory holding costs with minimal stockouts
• Better alignment between inventory and maintenance demand
• Enhanced asset availability and reduced downtime
• Strengthened spare parts governance and record accuracy
Instructional Methdology
The course follows an interactive and solution-driven format:
• Briefings – Theory and frameworks for spare parts and technical warehousing
• Case Studies – Issues in spare parts excess, aging stock, and traceability failures
• Workshops – Classification, demand analysis, reorder point setting
• Peer Exchange – Industry comparisons and participant-led discussions
• Tools – Spare parts matrix templates, stock audit sheets, and bin card samples
Course Outline
DETAILED 5-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: Spare Parts Inventory Fundamentals
Module 1: Characteristics of Spare Parts Inventory (07:30 – 09:30)
• Types of spare parts: critical, fast/slow-moving, obsolescent
• Spare parts lifecycle and maintenance dependency
Module 2: Stock Keeping and Data Accuracy (09:45 – 11:15)
• Bin cards, tagging, barcoding, ERP integration
• Master data management for spares
Module 3: Warehouse Layout for Spare Parts (11:30 – 01:00)
• Zoning by frequency, size, and temperature sensitivity
• Storing irregular, bulky, or fragile parts
Module 4: Workshop – Technical Stores Layout Planning (02:00 – 03:30)
• Participants redesign a parts warehouse layout based on case data
Day 2: Classification and Demand Analysis
Module 1: Spare Parts Classification Systems (07:30 – 09:30)
• ABC, FSN, XYZ, VED, and SDE models
• Multi-dimensional inventory categorization
Module 2: Forecasting and Demand Planning (09:45 – 11:15)
• Maintenance-driven vs. consumption-driven demand
• Predictive modeling and lead time buffers
Module 3: Replenishment Models and EOQ (11:30 – 01:00)
• Minimum–maximum systems, safety stock, reorder points
Module 4: Workshop – Spare Parts Classification Exercise (02:00 – 03:30)
• Teams apply classification logic to a real dataset
Day 3: Inventory Optimization and Control
Module 1: Reducing Surplus and Obsolescence (07:30 – 09:30)
• Slow/non-moving stock identification
• Cannibalization, resale, and disposal strategies
Module 2: Cycle Counting and Audits (09:45 – 11:15)
• Count frequency by criticality and value
• Investigating variances and improving accuracy
Module 3: KPI Development for Spare Parts (11:30 – 01:00)
• Stock turnover, fill rate, service level, inventory age
Module 4: Workshop – KPI Dashboard Design (02:00 – 03:30)
• Participants build an inventory monitoring dashboard
Day 4: Process Optimization and Issue Control
Module 1: Receipt, Issue, and Return Processes (07:30 – 09:30)
• Gatekeeping, tagging, quality control
• Return-to-stock procedures and issue logs
Module 2: Spare Parts Storage Safety and Compliance (09:45 – 11:15)
• Chemical, flammable, and hazardous parts handling
• Physical safeguards and labeling standards
Module 3: Vendor and Repairable Parts Management (11:30 – 01:00)
• Repair cycle tracking, warranty monitoring, core returns
Module 4: Workshop – Inventory Process Mapping (02:00 – 03:30)
• Participants design workflows for receiving and issuing spares
Day 5: Governance, Technology & Final Planning
Module 1: Policies and SOPs for Spare Parts Management (07:30 – 09:30)
• Access control, roles, authority levels
• Governance and audit readiness
Module 2: Spare Parts and WMS/ERP Integration (09:45 – 11:15)
• Inventory modules in SAP, Oracle, and Maximo
• Barcode, RFID, and scanning tools
Module 3: Final Project – Spare Parts Optimization Plan (11:30 – 01:00)
• Teams develop full inventory optimization recommendations
Module 4: Presentations and Course Wrap-Up (02:00 – 03:30)
• Team presentations and feedback
Certification
Participants will receive a Certificate of Completion in Warehouse Operations & Spare Parts Inventory Control & Optimization, recognizing their ability to manage spare parts stores and optimize inventory levels in line with maintenance and operational needs.