MRO Inventory Optimization
The right part, in the right place, at the right time. PM2 resets your storeroom and rebuilds the data behind it, so critical spares are on the shelf, parts are found on the first trip and you stop buying stock you already own.
- 25+years managing maintenance and spare parts inventory
- 125+combined years of experience on PM2's leadership team
- 1,000+storerooms and plants PM2 has worked in
- 16industries served, from aerospace to healthcare
Certified women-owned business
PM2 implements the plan it recommends
Many inventory management companies and consultants make recommendations and leave you to carry them out. PM2 implements the plan it recommends, start to finish or in phases. That includes resetting the physical storeroom: layout, storage equipment and organization. It also means ensuring a complete and accurate database through data collection and labeling. Then PM2 trains your team on the new processes, so the investment holds.
PM2's own crews do the work, in all 50 states, Canada and Mexico.
How a PM2 project runs
- 01
Qualifying call
A short conversation about your site, your system and what's going wrong.
- 02
Initial site assessment
PM2 evaluates the physical environment, reviews your data and systems, and interviews key process owners.
- 03
Assessment report and proposal
Findings, recommendations and a roadmap, offered à la carte to fit your timeline, budget and resources.
- 04
Implementation
PM2's own crews reset the storeroom, build the data and apply the labels.
- 05
Post-project
Results measured, the database maintained and your team trained.
Why a storeroom cleanup doesn't cut MRO inventory
A cleanup makes the shelves look better for a few months. MRO inventory optimization changes how much you carry. PM2 analyzes your inventory data, lines up purchasing with maintenance, and sets stocking levels from usage history, lead times and how critical each part is.
Most of the excess hides in plain sight: the "just in case" stock someone ordered after a bad breakdown, the bulk buy that never got used, and the same bearing entered under three part numbers. Each one ties up cash and shelf space.
The job is to take that out while the parts that keep a line or a unit running stay on the shelf.
Storeroom cleanup vs. MRO inventory optimization
Both have a place. Only one changes what you carry and what you spend.
| Item | Storeroom cleanup | MRO inventory optimization |
|---|---|---|
| Starts with | The shelves | Your inventory data and an inventory cost baseline |
| Changes | How the storeroom looks | How much you stock, where it lives and when you reorder |
| Stocking levels | Left as they were | Min/max and reorder points set from usage, lead time and criticality |
| Duplicate parts | Often moved, rarely removed | Found in the data and merged into one record |
| How long it holds | Until old habits come back | As long as the processes behind it are followed |
Seven questions PM2 answers before anything moves
These are the questions PM2 works through before anything moves. The answers decide how much space you need, where things go and what you stop buying.
- B-01
How much do we need vs. have?
Stocking levels checked against real usage and supplier lead times.
- B-02
How much is "just in case"?
The buffer added after one bad breakdown, and the bulk buys that never moved.
- B-03
Which parts are critical?
The spares that keep the plant running stay protected, whatever else changes.
- B-04
Is one item in several places?
Family grouping: one product per location and one location per product.
- B-05
Will it all fit?
Storage specified for your inventory, your space and the weight and size of what you keep.
- B-06
Does it meet OSHA requirements?
Items with special storage or handling rules identified and stored to match.
- B-07
Does the plan follow 5S?
Lean and 5S practice built into the layout so it stays organized.
- B-08PM2 consulting
Need a starting number?
An inventory cost baseline shows what you spend today to hold and manage inventory.
What PM2's crews do on site
Implementation runs in four phases. Every item stays accessible throughout, so maintenance keeps working while the storeroom changes around it.
- STEP 01
Stage and rebuild
Inventory is removed and staged, old shelving comes down and new storage equipment goes in, with a location schema for every shelf and drawer.
- STEP 02
Move and organize
Parts are grouped by commodity, one SKU to each bin location, with duplicates reduced and locations consolidated.
- STEP 03
Build the database
Each item is captured with its manufacturer name and number, a standardized description, location and quantity, and delivered as a clean item master.
- STEP 04
Label and train
Barcode labels go on every location, and your team is trained on the processes that keep the storeroom accurate.
Every part gets one record and one address
This is what PM2's data work produces. Records are built to the specification of the system you already run.
Location address
- B1Room
- S1Aisle
- R9Cabinet or rack
- ADrawer or shelf
- 05ABin
Every shelf, drawer and bin gets an address like this, printed on its label, so a technician can walk straight to the part.
Example item record
- Description
- BEARING, BALL 17MM ID 40MM OD 12MM W 2SHIELD
- Commodity
- Power transmission
- Manufacturer
- EBC
- Mfr. number
- SS6203 2RS
- Location
- B1-S1-R9-A-05A
- Quantity
- 2
PM2 builds data for SAP, Maximo, Oracle, Infor, eMaint, MaintainX, MP2, L2L and other systems.
Questions about MRO inventory optimization
What maintenance and purchasing leaders ask before they start.
What is MRO inventory optimization?
It's the work of reducing excess and duplicate MRO inventory while making sure critical spare parts stay available. It goes further than a cleanup: PM2 analyzes your inventory data, aligns purchasing with maintenance and sets stocking levels you can hold over time.
How do you reduce MRO inventory without causing stockouts?
Part by part, with data. PM2 sets min/max levels and reorder points from historical usage, lead times and how critical each part is, so the parts that protect uptime stay stocked while excess and duplicates come out.
Who does the work?
PM2's own crews do everything, from taking down old shelving to applying the last label. PM2 can run the whole project or only the phases your budget and timeline allow.
What size projects does PM2 take on?
Projects run from about a week to 18 months, and there's no minimum size. The largest storeroom PM2 has reset held more than 40,000 SKUs in 250,000 square feet, worth over $40 million.
Is PM2 a software company?
No. PM2 isn't a CMMS or ERP, and it isn't a reliability engineering firm. It builds the data for the system you already run, to that system's specification, and resets the physical storeroom around it.
What should we measure to know it worked?
Set an inventory cost baseline before anything changes. After that, track fill rate, service level, backorders, emergency orders, inventory turns and obsolete inventory.
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Let PM2 transform your inventory, databases and processes.
Tell us what's sitting in your storeroom and what it's costing you. PM2 starts with your objectives and builds the plan from there.