Working capital, downtime, and compliance in one deployment, across a multi-plant specialty chemicals network running lithium, bromine, and catalyst production lines.
Spare parts, criticality, and maintenance planning had been managed independently across roughly 18 sites on a mix of SAP and legacy CMMS platforms, the pattern typical of spare parts management run plant by plant rather than as one network.
Working capital sat locked in duplicated inventory, emergency procurement carried a heavy cost premium, and safety-critical rotating equipment was exposed to stockout risk with no enterprise-wide visibility to catch it. MRO360 was deployed as an intelligence layer above the existing systems, with nothing replaced and no disruption to plant operations.
In a continuous chemical process, a stockout on a certified part is not only a cost event. It is a potential safety, environmental, and regulatory event, carried independently at every plant in the network until now.
The download covers the full technical detail behind this deployment, module by module, along with the governance model that let it run without touching a single plant's ERP.
Get the full story behind the transformation.
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All nine modules were deployed in full, none descoped, spanning visibility, criticality, working capital, and network-wide forecasting and planning.
Finding any part across every plant, and scoring both equipment and parts by real criticality, not spend alone.
Modules 1–3Clearing dead stock and discontinued parts before they become write-offs or unplanned exposure.
Modules 4–5Forecasting demand against the real turnaround calendar, setting living reorder points, and moving surplus inventory between plants before a new purchase order is raised.
Modules 6–9The MRO360 deployment falls within the ranges documented for comparable chemicals and petrochemical customers.
| Area | Outcome |
|---|---|
| Working capital in MRO inventory | $10M to $40M released |
| Emergency procurement | Reduced 40% to 60% |
| Unplanned downtime | 25% to 40% reduction on safety-critical equipment |
| Turnaround parts availability | 99%+ at mobilisation |
| Demand forecast accuracy | Above 95% once tuned to the plant calendar |
Ranges reflect outcomes MRO360 documents for comparable chemicals deployments. The full breakdown, module by module, is in the downloadable case study.
Accountable for network-wide emergency spend, turnaround readiness, and inventory performance across multiple chemical plants.
Responsible for spare parts availability, stocking policy, and certified-substitute compliance across a multi-site SAP environment.
Managing work order backlogs across chemical plants and confirming certified parts availability before every planned turnaround.
Deploying an intelligence layer above existing SAP instances without replacement, migration, or IT disruption.
This case study covered the six operational pressures behind one deployment, all nine Spare Parts Management modules, the Work Order Management rollout, and the complete before-and-after results. If you're weighing where your own plants stand before a decision like this, start with a benchmark.
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