MRO Planning helps businesses keep the right parts and supplies available before a repair becomes an emergency. The stakes are real: a NIST study of manufacturers found that those relying more heavily on preventive and predictive maintenance had 52.7% less unplanned downtime than those relying most heavily on reactive maintenance. When equipment stops, the cost can extend beyond the repair itself to delayed work, idle employees, and rushed orders. A plan for maintaining equipment and stocking critical parts can help keep operations moving.
What is MRO Planning?
MRO stands for maintenance, repair, and operations. Planning for maintenance, repair, and operations includes having the appropriate parts, supplies, and equipment to keep your business running smoothly.
Think of MRO planning like keeping a well-stocked first aid kit for your facility. You hope you won’t need every item today, but when something breaks or wears out, having the right supplies on hand helps you fix the problem quickly and keep operations moving.
Common MRO Gaps that Lead to Unplanned Downtime
Downtime is detrimental to a business, causing loss of revenue, decreased production hours, missed deadlines, and increased repair costs, often involving expedited shipping or overtime. Becoming aware of MRO gaps in your business can help prevent unplanned downtime and keep your business running smoothly.
Inaccurate Spare Parts Inventory
There are few things worse than expecting to have something only to find out it’s not available. Inventory records may show a part is in stock, but when it’s needed, it turns out it’s already been used or moved. It’s important to supplement inventory records with regular counts to update inventory records as parts are ordered, received, and used. Your inventory should also set reorder levels for frequently used supplies to ensure a regular stock is available to reduce unplanned downtime.
No Plan for Critical Replacement Parts
Not every part needs to be kept on hand, but some can bring operations to a halt when they fail. Identify the replacement parts needed for your most important equipment and keep backups of those that would be difficult to source quickly. Consider supplier lead times when deciding what to stock, especially if waiting for a part would mean days of downtime.
Waiting Until Equipment Fails to Order Supplies
Staying ahead of supply demands is essential. Waiting until equipment fails can cause emergency or urgent orders to be made, which can come with higher costs. If you don’t pay for rushed shipping, that could mean longer downtime for your business. Analyzing past usage and maintenance schedules can give you an idea of when supplies may be needed, allowing you to stay ahead of repairs.
Unclear Communication Between Maintenance and Purchasing
Communication between departments can cause a gap in your MRO planning. Maintenance may know a part is needed, but purchasing may not hear about it until the request is urgent. Establishing a clear process for reporting parts usage and requesting maintenance can aid in MRO planning. Ensure transparency by giving both teams access to current inventory and order statuses.
Long Lead Times from Suppliers
A part that was easy to get last time may take weeks to arrive when you need it again. Check lead times for critical items and factor them into your reorder levels. Talk with your distributor before a shortage becomes an emergency. Our team at C.E. Thurston looks at the problem you’re trying to solve, whether that means finding a hard-to-find part, identifying an alternative, or exploring a retrofit that can keep your business moving.
No Consistent Process for Tracking Parts Usage
If you don’t know which parts are being used or how often, it’s difficult to plan what to keep in stock. Record the parts used for each piece of equipment and review that information regularly. Over time, those records can reveal recurring needs and help you adjust inventory levels and maintenance schedules before supplies run low.
Are you experiencing these gaps?
Let our team of MRO experts guide you to a solution.
Better MRO Planning Checklist
Keep Your Business Moving with Better MRO Planning
Keeping your business moving is easier when you plan for maintenance, repairs, and operations.
- ZStart by identifying the parts your most important equipment depends on.
- ZKeep inventory records current, review maintenance needs regularly, and order supplies before they become urgent.
- ZWhen a part is difficult to find, or an existing setup needs a new solution, C.E. Thurston can help you explore your options and keep your operations moving.
How C.E. Thurston Can Help You
Our distribution team supports industrial and commercial operations with expert guidance, technical support, and service-driven solutions that help customers reduce downtime and improve efficiency. With decades of experience and a deep understanding of facility needs, we provide proactive support that strengthens safety, productivity, and overall operational performance.
- Plant surveys for the products and materials you rely on
- Standardization recommendations to improve procurement and consistency
- Vendor-managed inventory (VMI) and vending programs
- Safety training for facility teams
- Installation of material handling products to enhance workplace safety and productivity
