In the heavy equipment industry, uptime is everything. For one of the largest heavy equipment dealers in the western USA, assuring the "on-time and in-full" delivery of repair and overhaul parts is the heartbeat of its business. To achieve this, the company leveraged a powerful component of the Inventory Capital Solutions (ICS) advanced planning system by FDC: Integrated Maintenance-Repair-Overhaul (MRO) Planning.
The Complexity of Component Rebuilds
Managing the parts needed for a massive engine or machine overhaul is a logistical puzzle. Traditional systems often struggle to synchronize independent demand with the specific parts required for scheduled maintenance events.
How ICS Synchronizes the Shop Floor
The company utilized the MRO planning and provisioning features of ICS to transform its rebuild process.
Exploding Bills of Materials (BOMs). The system "explodes" MRO events into their component parts via BOMs, identifying every part and quantity needed for a specific job.
Time-Phased Provisioning. Parts are synchronized to arrive at the exact moment the MRO event is scheduled to take place.
Automated Non-Stock Ordering. Unlike traditional systems, ICS can automatically order "Non-Stock" parts if they are identified on an MRO Bill of Materials, preventing last-minute shortages.
Integrated Workflow. The system interfaces directly with the company's MRO schedules, creating a single, cohesive workflow that eliminates the need for manual spreadsheets.
A Proven Track Record
The company began by cautiously testing this capability with just five MRO jobs in the first few weeks. Within 18 months, the company had successfully processed 861 exchange component rebuilds using the system. The result? Work stoppages due to parts shortages were largely avoided, all without needlessly inflating general stock levels. By integrating shop-floor needs with intelligent supply chain technology, the company set a new bar for operational excellence.
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