Maintenance Repairs & Overhaul Planning Platform
An integrated, data-driven approach to optimising high-value spares, repairs, and inventory across mining operations.
Key complexities in Vendor Managed Inventory (VMI) and mine-owned high-value components
Challenges; symptoms and opportunities
Typical Symptoms
- Limited visibility (obtained from and provided to OEMs)
- Instability of the medium-term maintenance plan
- Quality of maintenance plans
- Limited inclusion and collaboration with the supply chain and OEMs in medium-term planning
- High level of complexity in managing and integrating data and plans across the key stakeholders
- Lack of parts availability
- Reactive and unscheduled requests to Supply Chain
- Limited use of integrated KPIs
Opportunities
- Evaluate maintenance capacity based on ACLM plans
- Lock in ACLM plans and start to measure deviations from original plans
- Budget tracking
- Lead time for decision making
- Stability of plans
- Increased visibility on where Reco and Pex units are in the system and updated information
relating to expected turnaround times - Visibility on stock in network & capability to collaborate and brainstorm plans
- Data management across the business landscape
- Integrated KPIs
- Platform to manage Demand & Supply across the entire landscape of multiple OEMs
Solution Elements: MROP Platform
Integrated solution approach of spare parts management across internal and external stakeholders
Fourier-E has developed a comprehensive Maintenance, Repair & Overhaul Planning (MROP) process and an accompanying software solution designed to optimise inventory management across both components and standard spare parts. This proposal outlines the strategic implementation of this MROP process, emphasising cross-functional collaboration, dedicated process ownership, and the integration of a robust software platform to support decision-making and operational efficiency.
Objectives
- Establish a structured and collaborative MROP process.
- Improve inventory visibility and control for components and spare parts.
- Enhance cross-functional decision-making across engineering, maintenance, supply chain, and finance.
- Leverage software to automate and optimize planning and forecasting.
- Strengthen supplier collaboration through materials management representation.
MROP Process Framework: Cross-Functional Collaboration
The MROP process will be driven by a collaborative team comprising:
- Engineering & Maintenance: Provide technical insights and maintenance planning.
- Supply Chain (Materials Management): Manage inventory levels and represent key OEM suppliers.
- Finance: Ensure alignment with budgetary and financial planning.
This team will operate as an integrated decision-making forum, ensuring that all aspects of MRO planning are considered holistically.
MROP Process Framework: Dedicated MROP Process Owner/Analyst
A dedicated MROP process owner or analyst will be appointed to:
- Oversee the end-to-end MROP process.
- Facilitate communication among stakeholders.
- Monitor performance metrics and continuous improvement.
- Ensure data integrity and process compliance.
Software Platform Implementation
Fourier-E’s MROP software solution will serve as the digital backbone of the process, offering:
- Inventory Optimization: Real-time tracking and forecasting of component and spare part needs.
- Data Integration: Seamless integration with existing ERP and maintenance systems.
- Analytics & Reporting: Advanced analytics for predictive maintenance and cost control.
- Supplier Collaboration Tools: Interfaces for OEM supplier engagement and performance tracking.
Benefits
- Reduced inventory carrying costs.
- Improved equipment uptime through better maintenance planning.
- Enhanced supplier performance and accountability.
- Streamlined decision-making and reduced planning cycle times.
Objectives
Solution Elements: MROP Platform
Integrated solution approach of spare parts management across internal and external stakeholders
MROP Platform
Platform capable of translating data inputs; modelling constraints and scenario simulating
Master data management & Audit logs
- Movement classes
- Filters
- Keeping track across the network
- Changes at vendors
- Workflow prompts
- Task assignments
- Calendar roll-out
- Plan changes and updates
- Supply history
- Manage supply orders
- Run simulation scenarios
- Flag exceptions
- Lead time review
- Updates
- Issuing history