How a Top Process Manufacturer Verified $21M in Savings and Reduced Outage Duration from Weeks to Days

Background

In process manufacturing, downtime compounds quickly. When spare parts are duplicated, misclassified, or positioned incorrectly, outages extend from days into weeks. For this global process manufacturer, excess inventory existed alongside material shortages that directly impacted outage timelines.

The problem was not inventory volume, but inventory accuracy and alignment.

key results at a glance

$21M

Verified Inventory Savings Accepted

3,000+

Duplicate Materials Identified

3 Days

Outage Duration Reduced from 4+ Weeks to 3 Days

2,200

Materials Identified at Risk of Stockout

Industry Context

Process manufacturing environments rely on continuous operations, where unplanned downtime carries significant production and financial risk.

MRO inventory must support reliability while adapting to complex asset dependencies, long lead times, and strict maintenance windows.

The Challenge

The organization faced growing challenges across its MRO inventory landscape:

  • Poor data quality and inconsistent inventory management processes
  • Excess and growing volumes of incorrect and duplicate MRO materials
  • Outdated stocking policies and static lead times
  • Significant discrepancies in inventory data across multiple ERP systems
  • A dedicated team of resources required to manually manage inventory strategy

Despite high inventory investment, the organization remained exposed to outage risk.

The Solution

The organization implemented a unified, AI-driven MRO inventory optimization platform to aggregate supply and material data across multiple ERP and EAM systems simultaneously. This enabled:

  • Identification and elimination of duplicate materials across sites
  • Revamping of outdated stocking policies and min/max levels
  • Improved visibility into materials at risk of stockout
  • Alignment of inventory strategies with asset criticality
  • Coordination across supply operations, procurement, maintenance, finance, and IT
  • Data-driven inventory decisions without requiring system replacement

This approach replaced manual, reactive processes with consistent, scalable inventory governance.

Outcome

  • $21M in verified savings accepted
  • 3,000+ duplicate materials identified and addressed
  • Outage duration reduced from more than four weeks to three days
  • 2,200 materials identified at risk of stockout

How Verusen Supports MRO Inventory Optimization for Process Manufacturers

Process manufacturing inventory environments demand accuracy, not just volume. Verusen supports process manufacturers by unifying fragmented MRO data and applying AI-driven analysis to identify duplication, outdated stocking policies, and inventory risk positions.

By aligning inventory strategies to asset criticality and real operating conditions, Verusen helps process manufacturers reduce excess inventory while improving outage preparedness and maintenance responsiveness.

Typical Improvements Process Manufacturers Can Expect

What improvement you can expect for your process manufacturing business:

  • Identification and elimination of large volumes of duplicate materials
  • Reduced outage duration through improved availability of critical spares
  • Improved visibility into inventory risk positions
  • Revamped stocking policies aligned to operational risk
  • Better coordination across supply operations, procurement, and maintenance
  • Reduced manual effort required to manage inventory strategy
  • Faster onboarding using existing MRO inventory data

Ready to Improve Inventory Accuracy and Reduce Outage Risk for Your Process Manufacturing?

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Frequently Asked Questions

What is MRO inventory optimization for process manufacturing?

It focuses on aligning spare parts availability with continuous production requirements while eliminating duplicate and incorrect materials that increase outage risk.

By ensuring critical spares are correctly stocked and visible, maintenance teams can complete outages faster without waiting on emergency sourcing.

Duplicate materials increase carrying costs, obscure true inventory levels, and delay maintenance when the correct part cannot be identified quickly.

Process manufacturers typically begin identifying duplication and risk shortly after onboarding, using existing inventory data without requiring a traditional data cleanse.