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Organizations worldwide are seeking to improve service to customers by more efficient deployment of their inventory and process rationalization For a Fortune Global 100 organization that provides spare parts and overhaul services for expensive long product life equipment a rapid analysis and assessment of their operations revealed multiple simple process and system initiatives which will result in considerable savings to the bottomline The problem A Fortune Global 100 organization is in the business of manufacturing aircraft engines for both civil and military applications As a trend replicated in various manufacturing organizations this organization has started focusing on its after market services business Over recent years the organization has made strategic acquisitions of elaborate facilities for carrying out engine overhauls With increasing competitive pressures profit margins on the sale of aircraft engines have been on a steady decline At the same time engine repair and overhaul business has been accounting for an increasingly larger share of the organizations profits Due to the systemic acquisition of service shops across the globe the organization has a plethora of IT systems that hold information on material inventory but there was no automated system to get an integrated view of material inventory This had a direct bearing on the customer service levels of the organization Some service shops have attempted to please their customers by purchasing high value rotables on an ad-hoc basis to meet their urgent requirements To avoid stock-out situations there is a routine practice of maintaining excess rotables in service shops to meet unforeseen demand This has led to a practice of virtual turf wars among service shops on rotables such that rotables are apparently under use while in reality they are not so As a result of such malpractices and given the high cost of rotables the organization as a whole ends up with huge inventory costs These costs put tremendous pressures on the bottomline as well The recent slowdown in
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