What a diagnostic revealed inside a global manufacturer's spare-parts inventory, computed directly from the operator's own system extract, not estimated, not benchmarked.
A multinational manufacturer operating dozens of mills and plants, whose estate had recently grown through a major corporate combination. With the combination came a familiar inheritance: multiple ERP environments, the same parts held under different records at different sites, and a group-wide mandate to deliver synergies and release cash, but limited dedicated capacity to work through spare parts inventory site by site.
MRO360 was deployed as a governed intelligence layer on the operator's existing ERP estate, reading the records already in each system, generating recommendations across sites, and writing approved changes back with a full audit trail.
Every recommendation is explainable and human-approved, nothing executes without sign-off. Because it works from each system's own records, it operates today while broader post-combination harmonisation proceeds, rather than waiting for it.
All figures in this case study are expressed as ratios to protect the customer's confidentiality. Every finding was computed directly from the customer's own system extract, not estimated, not benchmarked.
The mills carried detailed inventory records: stock levels, maximum-level settings, movement history, criticality flags. What was missing wasn't the information, it was the capacity to interrogate it at estate scale and turn the answers into governed action.
The download covers the full diagnostic findings, the module-by-module detail behind each one, and how the business case was sized and de-duplicated to survive finance review.
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Every figure below was computed directly from the customer's own system extract, de-duplicated, and reviewable line by line.
| Métrico | Resultado |
|---|---|
| Dead capital | 42% of inventory value, no goods movement in 24 months |
| Addressable pool | ~Half of analysed inventory value, de-duplicated |
| Time to findings | Days, from system extract to validated results |
| Base case capture | A conservative 10% of the addressable pool |
| Recurring saving | ~22% per year in carrying cost on capital released |
| Engagement cost vs. pool | Identified pool exceeded engagement cost by two orders of magnitude |
Excluded from the headline case entirely: avoided downtime from better critical-spare availability, reduced expedite purchasing, planner productivity, and warehouse-space recovery, treated as additional upside rather than baked into the numbers above.
Accountable for MRO performance across mills that grew through corporate combination, with no consolidated view.
Closing the record ambiguity between business units that leaves surplus at one site invisible to another.
Evaluating duplicate holdings across newly combined sites as a fast, cash-positive synergy lever.
Managing multiple ERP environments post-combination, without waiting for full harmonisation to act.
If your estate has grown through combination, or your dormant stock has never been measured, the same diagnostic can be run on your own extract, in days.
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