In the construction industry, excavators, loaders, cranes, and graders can’t be considered complete without machine spares. These machines are the backbone of construction sites. However, when a crucial part deteriorates, the result is increased downtime, rising costs, and increased project durations. It is, therefore, essential that construction companies build an adequate machine parts inventory. This is not only an important activity; it is a key requirement of any construction business that relies on machine functionality. In this blog, we shall highlight the best practices to achieve adequate machine parts inventory.
Before we begin, it’s important to highlight that SINTRA is currently the most significant player in the market for heavy equipment solutions. With an emphasis not just on spare parts but after-sales services as well, SINTRA ensures continuity for construction firms operating across the Middle East, Africa, CIS, and APAC regions to function as usual. Whether you’re looking for original spare parts from brands such as Volvo, JCB, Cummins, and Komatsu, and other major brands for that matter, SINTRA’s knowledge and availability will provide an ideal starting point for any spare parts initiative.
1. Know Your Fleet and Your Needs
A well-organized spare parts inventory starts with the following information about the machines you use:
- Identify critical equipment: Make a list of all the machines in your possession, including the age, model, and name of the manufacturer.
- Analyze failure history: Look at the records of previous maintenance that are stored, and see which components fail and how.
This baseline measurement allows you to focus on the most critical elements while avoiding unnecessary investment in inventory. This measurement also makes forecasting more accurate, which is a vital component in planning inventory effectively.
2. Spare Parts Classification based on Criticality
Not all parts will carry the same level of priority. Some parts will cause a machine to stop running altogether should they fail. These types of parts include hydraulic pumps or engine belts. Others will not affect the machine running time much and include small bolts or trim parts.
A best practice would be to code components using approaches like:
- Critical vs. non-critical
- High-value vs. low-value
- Essential and non-essential options
This classification system is beneficial to ensure that high-impact parts are stocked at all times and other parts necessary for operations are ordered when demands are received.
3. Leverage Technology for Real-Time Inventory Management
Manual inventory tracking is a time-consuming and error-filled activity that ought to be replaced not only with inventory management software but even with a computerized maintenance management system that can:
- Monitor stock levels in real-time.
- Auto-flagging when stock runs low
- Maintain part histories and lead time data
- Produce alerts for Reorder Points
With real-time visibility, stockout conditions that result in project delays and overstocked conditions that consume working capital can be avoided.
4. Set Smart Reorder Points & Safety Stock
Effective spare parts inventory means achieving the perfect balance between availability and cost. Two key metrics must be established:
- Reorder Point: the optimum level of inventory from which you start replenishing the parts when you are about to finish with them.
- Safety Stock: Additional stock kept on hand in case markets grow unexpectedly or suppliers take longer than expected.
Take into consideration the average lead times and the importance of the part when determining safety stock levels. In other scenarios, it may take longer to order and deliver a hydraulic excavator pump compared to bolts meant for a secondary machine.
5. Streamline Supplier Relationships
Having a reliable supplier means a great deal. Nurturing a relationship with a reputable supplier like SINTRA, with its array of genuine spare parts, will certainly make a world of difference to your inventory efficiency. This is how:
- Lowering lead times
- Bargain for favorable prices
- Obtain information on trends in part availability.
By having a strong portfolio of high-quality parts and being supportive of construction companies, SINTRA is able to improve the management of construction companies’ stock.
6. Warehouse Organization for Easy Access
Inventory is a matter not only of what is possessed, but also of its accessibility. Some ways it should always be done are:
- Implementing Clear Labeling and Tagging
- By using shelving that is set up in a way that groups similar
- Implementing bar-code or QR-code scanning technologies to improve quick scanning and tracking
- Designing Logical Zones for High-Priority Components
An organized inventory storage system increases search efficiency, eliminates missing inventory, and facilitates faster maintenance work.
7. Audits & Improvement Process
Creating an inventory process is not an end project, but rather an ongoing operation. An inventory audit will help eliminate unnecessary inventory, perfect inaccuracies, and ensure inventory levels match changing operational requirements.
These points should also be reviewed periodically:
- What is actually going too fast?
- What are the stagnations?
- Are reorder points relevant to actual usage?
Continuous improvement means that your inventory management system keeps pace with the growth of your business and vehicles.
8. Priority: Quality with Genuine Parts
While aftermarket parts might be price-effective, this could result in breakdowns occurring on a more frequent basis. When it comes to choosing high-quality spare parts, SINTRA would be considered ideal, ensuring there are no compatibility or reliability issues, which would be essential towards ensuring less downtime for vehicles within your fleet.
Conclusion: The Strategic Advantage of Efficient Spare Parts Inventory
An effective inventory system for your spare parts turns your maintenance activities from fire-fighting activities to readiness. You cannot go wrong with permanent readiness. By understanding your machine demands, doing proper part categorization, using technology, and collaborating with companies like SINTRA, you are creating an enabling environment, whether it concerns uptime, cost, or project timelines. In the cutthroat market that is the construction business, having a strategy relating to spare parts, as outlined above, is not only advisable but an advantage.
