The Critical Role of MRO Supply Chains in Australia and New Zealand

In Australia and New Zealand (ANZ), Maintenance, Repair, and Operations (MRO) supply chains are vital to the smooth functioning of many sectors, including manufacturing, mining, healthcare, and infrastructure. Ensuring that equipment is well-maintained, reliable, and ready for use is key to keeping operations running efficiently. However, MRO supply chains can also present significant challenges, including unpredictable demand, high operating costs, and fragmented supplier bases.

For organisations in ANZ, optimising MRO supply chains is not just about reducing costs but also improving service delivery, sustainability, and overall operational resilience. This article explores the unique aspects of MRO supply chains in ANZ and identifies opportunities for improvement in procurement and supply chain management. We will also discuss how Trace Consultants can assist organisations looking to take on MRO optimisation projects, helping them realise tangible cost savings and performance improvements.

Overview of MRO Supply Chains in ANZ

MRO supply chains ensure that organisations have the essential spare parts, tools, equipment, and services needed for maintenance and operations. While MRO goods are not directly part of the final product, they are indispensable for keeping equipment and facilities running smoothly. Key categories within MRO include:

• Spare Parts and Consumables: Bearings, gaskets, belts, filters, and fasteners.
• Tools and Equipment: Hand tools, power tools, welding machines.
• Maintenance Services: Regular inspections, repairs, and installations.
• Facilities Management: Electrical components, cleaning supplies, HVAC systems.
• Personal Protective Equipment (PPE): Helmets, gloves, safety glasses, and boots.

Unique Challenges of MRO Supply Chains in ANZ

1. Geographical Complexity:The geographical spread of industries in ANZ, particularly in mining and agriculture, presents a unique logistical challenge. Many operations are located in remote or regional areas, making it difficult to secure timely deliveries of MRO supplies. Dependence on international suppliers further complicates logistics and introduces risks around long lead times and supply chain disruptions.
2. Supplier Fragmentation:MRO supply chains in ANZ are often characterised by a fragmented supplier base, with many organisations managing relationships with hundreds of suppliers for various MRO items. This complexity leads to inefficiencies, inconsistent service levels, and difficulties in obtaining economies of scale.
3. High Inventory Costs:Carrying large inventories to mitigate the risk of stockouts is common practice in MRO supply chains. However, this approach ties up capital and results in high carrying costs, especially for parts that may only be required infrequently. Balancing stock availability with cost containment is a major challenge for many organisations.
4. Unpredictable Demand:The need for MRO items can be highly variable, depending on factors such as equipment breakdowns, seasonal operations, or unexpected maintenance requirements. The unpredictability of demand makes inventory management difficult and increases the likelihood of either excess stock or stockouts, both of which impact operational efficiency.
5. Sustainability Pressures:Increasingly, companies in ANZ are being held accountable for the environmental impact of their operations. This is placing pressure on MRO supply chains to adopt sustainable procurement practices, reduce waste, and find more eco-friendly solutions for maintenance and repairs.

Opportunities for Improvement in MRO Supply Chains

1. Centralised Procurement and Supplier Rationalisation:
2. One of the most effective ways to reduce complexity in MRO supply chains is through centralised procurement and supplier rationalisation. By consolidating the supplier base and centralising procurement functions, organisations can negotiate better pricing, standardise products, and improve service levels.
3. • How Trace Consultants Can Help: Trace Consultants specialises in helping organisations centralise procurement operations, rationalise suppliers, and establish long-term strategic partnerships with high-performing vendors. This results in lower administrative costs, better pricing, and more reliable service delivery.
4. Data-Driven Demand Planning and Inventory Optimisation:
5. Leveraging advanced data analytics and predictive modelling is essential for better forecasting of MRO needs. By analysing historical data, equipment maintenance schedules, and usage patterns, organisations can optimise their inventory levels, reducing excess stock while ensuring critical parts are always available.
6. • How Trace Consultants Can Help: Trace can implement advanced demand planning tools that integrate historical usage data and maintenance schedules. By optimising inventory, organisations reduce holding costs and improve working capital without sacrificing service levels.
7. Cost-Out Programs and Strategic Sourcing:
8. Implementing cost-out programs and strategic sourcing initiatives can drive significant cost savings in MRO supply chains. A thorough spend analysis can uncover opportunities for supplier consolidation, alternative sourcing, and cost negotiation, ultimately reducing the total cost of ownership.
9. • How Trace Consultants Can Help: Trace Consultants offers deep expertise in spend analysis and category management, identifying areas where cost savings can be achieved. We assist organisations in negotiating better contracts with suppliers, leveraging volume purchases, and reducing the overall cost of MRO goods and services.
10. Automation and Digital Procurement Solutions:
11. Automating the procurement process through digital platforms not only reduces manual workloads but also enhances visibility and control over spending. Automating procure-to-pay (P2P) processes and using e-procurement platforms allow organisations to streamline their purchasing, improve accuracy, and reduce administrative overheads.
12. • How Trace Consultants Can Help: Trace Consultants can support the implementation of digital procurement solutions tailored to MRO needs. We work with organisations to automate their procurement workflows, improve data accuracy, and enhance compliance across the purchasing process.
13. Vendor-Managed Inventory (VMI) and Supplier Collaboration:
14. Vendor-Managed Inventory (VMI) programs are an effective way to reduce inventory holding costs and improve service reliability. By shifting inventory management responsibility to suppliers, organisations can ensure they always have the right parts on hand without the need for excessive stock.
15. • How Trace Consultants Can Help: Trace helps organisations set up VMI arrangements with key suppliers. We facilitate the negotiation of service agreements, ensuring that suppliers are responsible for maintaining stock levels and ensuring timely replenishment, which frees up capital for the business.
16. Sustainability in MRO Supply Chains:
17. As sustainability becomes an increasing priority for organisations in ANZ, MRO supply chains must adopt more eco-friendly practices. This includes sourcing sustainable materials, reducing waste, and exploring circular economy initiatives such as refurbishing or recycling equipment.
18. • How Trace Consultants Can Help: Trace is at the forefront of sustainable supply chain practices. We work with businesses to integrate sustainability into their MRO procurement processes, identifying opportunities to reduce their environmental impact while still maintaining cost efficiencies.

Case Study: Transforming an MRO Supply Chain in the Mining Sector

A major mining company in Queensland faced considerable challenges with its MRO supply chain due to the remote location of its operations, unpredictable demand for spare parts, and a fragmented supplier base. With high inventory costs and inconsistent service levels affecting operational efficiency, the company sought help from Trace Consultants to optimise its MRO processes.

Solution and Results:

• Supplier Rationalisation: Trace Consultants worked with the company to reduce its supplier base from over 120 to just 15 strategic partners. This consolidation resulted in improved pricing, stronger supplier relationships, and better service levels.
• Inventory Optimisation: By integrating predictive maintenance systems with their MRO supply chain, Trace enabled the company to reduce excess inventory by 25%. Predictive analytics helped forecast spare part requirements more accurately, leading to a more efficient use of working capital.
• Vendor-Managed Inventory (VMI): Trace facilitated a VMI program with key suppliers, ensuring that critical spare parts were always available on-site, reducing the need for costly express shipments.
• Sustainability Initiatives: Trace assisted the company in implementing sustainability initiatives, including refurbishing worn parts instead of replacing them and sourcing energy-efficient equipment, contributing to both cost savings and reduced environmental impact.

Through these initiatives, the mining company reduced its overall MRO costs by 20% while improving service levels and ensuring operational continuity in its remote locations.

The Role of Technology in MRO Optimisation

Looking ahead, technology will continue to play a transformative role in MRO supply chains across ANZ. Advancements in automation, artificial intelligence (AI), and 3D printing offer new ways to improve efficiency, reduce costs, and enhance the service delivery of MRO operations.

1. AI and Machine Learning for Predictive Maintenance:AI-driven predictive maintenance systems can anticipate equipment failures before they occur, allowing organisations to schedule repairs and order spare parts in advance. This reduces unplanned downtime and ensures that the necessary MRO items are on hand when needed.
2. 3D Printing for On-Demand Spare Parts:Additive manufacturing (3D printing) can be used to produce customised MRO parts on demand, particularly in industries such as mining and manufacturing where certain parts are difficult to source. This capability reduces reliance on external suppliers and long lead times, enabling faster repairs and less downtime.

Optimising MRO supply chains in Australia and New Zealand offers significant opportunities for organisations to reduce costs, improve service delivery, and enhance operational resilience. Centralised procurement, inventory optimisation, strategic sourcing, and digital solutions are key strategies that can drive improvements in MRO supply chains. Moreover, adopting sustainable practices and leveraging advanced technologies such as AI and 3D printing will be critical to future-proofing MRO operations.

How Trace Consultants Can Help:

At Trace Consultants, we specialise in helping organisations across ANZ transform their MRO supply chains. Our experts provide tailored solutions in procurement, supplier management, and inventory optimisation, while integrating cutting-edge technology and sustainability initiatives to drive lasting improvements. Whether you're looking to reduce costs, improve service levels, or enhance your sustainability credentials, Trace Consultants can guide you through every step of your MRO optimisation journey.

Through our collaborative approach and deep expertise, we ensure that your MRO supply chain becomes a source of competitive advantage, delivering the reliability and efficiency your business needs to thrive in the ANZ market.

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Contact us today, trace. your supply chain and procurement consulting partner.

Asset Management and Maintenance by James Allt-Graham

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Through the life of an asset the maintenance costs can vary dramatically but typically range between 2% and 5% of the purchase costs. Over time, once upgrades are implemented, it is common for the cumulative cost of maintenance to be greater than the original purchase cost. Depending upon the nature of the asset, the need to undertake preventative maintenance, respond to corrective maintenance needs and plan for minor and major upgrades in functionality can create complex planning and supply chain challenges.

What are maintenance management systems?

Maintenance management systems have assisted to drive efficiencies in the provision of maintenance services. The ability to plan corrective maintenance tasks, schedule skilled labour and arrange for spare parts and consumables to be available can be managed in a more dynamic environment, which enables asset downtime to be minimised and utilisation of maintenance labour and equipment to be optimised.

Health and Usage Monitoring Systems

However, we see a significant opportunity to take this further. In our experience, the vast majority of assets are still maintained based on time-based routines. Whilst the ‘Internet of Things’ (‘IOT’) has enabled a range of devices that are connected to the internet to monitor performance, the usage of these is still low. Commonly called HUMS devices (‘Health and Usage Monitoring Systems’) these enable asset usage and underlying condition (e.g. temperature, oil condition, fluid levels, weight etc) to be monitored. The maintenance tasks are only initiated when the usage or condition requires it, rather than simpler time-based routines. This has the following benefits:

- Maintenance is conducted when needed. Typically, this is less frequently but for high use assets, it may be more frequently to reduce the risk / impact of breakdown;

- Reduced use of materials like lubricants as changes are made when required not due to time;

- Increased maintenance up time; and

- Improved asset reliability.

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Environmental impacts of HUMS uptake

Increasingly, we are seeing additional benefits being derived that relate to the carbon / environmental impact of maintaining and operating these assets. By ensuring they are running efficiently (via HUMS data) and only maintained and repaired when needed, the overall cost and material consumed in reduced and the associated environmental footprint. This can be substantial for many asset types.

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Why is uptake relatively slow?

There are some key challenges that need to be overcome to derive these benefits:

- Overall integration of condition data into the maintenance management system (and triggering alerts to schedule maintenance); and

- The impact of more sporadic maintenance activity rather than more predictable time-based planning and scheduling. An uplift in planning capabilities including management of the supply chain is required.

An overarching plan of the benefits, IT integrations and impact on the maintenance planning methodology and approach needs to be synchronised.

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Case study

Aviation has been a leader in the use of HUMS data to inform maintenance. For example, engine sensors monitor all aspects of their operation and report performance and exceptions to expected performance conditions. This data is used to inform maintenance routines and to work with the Equipment Manufacturer to develop enhancements to improve performance and solve corrective maintenance needs.

Numerous technologies are available and are being deployed to improve safety and performance.  

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Next steps

In terms of next steps, we would advise clients who believe there are opportunities in their business to improve the efficiency and effectiveness of maintenance to adopt the following key steps.

1. Undertake a high-level diagnostic of opportunities and the root causes. Develop a comprehensive understanding of what could be changed and the benefits that it would create. If this looks significant, move forward with a cross functional team in your business.

2. Consider external advice to help refine the business case, identify options for the future state. The ability to call things ‘as they are’ and bring experience from other organisations can help to avoid ‘rebuilding the wheel’.

3. Develop a transition plan with clear short, medium and longer term benefits. Ensure the plan addresses issues relating to people (and organisational design), processes, technology, data and infrastructure.

4. Build a team to execute and share your success as you go!

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‍Contact us today, trace. your supply chain and procurement consulting partner.

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James Allt-Graham

Partner

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Reference

Surender, S. (2024) Unlocking the Potential of Aviation Safety: How Aircraft Health and Usage Monitoring Systems (HUMS) are Revolutionizing the Industry, Markets and Markets.

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Challenges and Opportunities in Naval Supply Chains

The maritime domain is a critical component of global security and economic stability, and for Australia, with its vast coastline and strategic maritime interests, maintaining an effective and efficient naval supply chain is paramount. The naval supply chain encompasses the entire lifecycle of ships, submarines, and other vessels, from acquisition and construction to maintenance, repair, and operations (MRO), sustainment, and eventual decommissioning. In the context of the recent AUKUS partnership, which promises a significant uplift in capabilities, Australian supply chains must undergo a step change to meet new requirements and challenges.

Spare Parts and Inventory Optimisation

One of the most significant challenges in naval supply chains is the management of spare parts. Naval vessels, including ships and submarines, are complex systems with thousands of components. Ensuring the availability of the right spare parts at the right time is crucial to maintain operational readiness and fleet capability.

Challenges

1. Complexity and Diversity: Naval vessels require a wide range of parts, from standardised components to highly specialised ones. The diversity and complexity of these parts make inventory management a daunting task.
2. Lead Times and Obsolescence: Long lead times for specialised parts and the risk of obsolescence pose significant risks. Parts must often be sourced from a global supply chain, which can introduce delays and uncertainties.
3. Forecasting and Demand Planning: Accurately forecasting the demand for spare parts is challenging due to the unpredictable nature of naval operations and the variability in component lifecycles.

Opportunities

1. Advanced Analytics and Predictive Maintenance: Leveraging advanced analytics and predictive maintenance technologies can significantly improve forecasting accuracy. By analysing historical data and operational patterns, naval forces can better predict when and where spare parts will be needed.
2. 3D Printing and Additive Manufacturing: These technologies offer the potential to produce spare parts on-demand, reducing dependency on traditional supply chains and mitigating risks associated with long lead times and obsolescence.
3. Collaborative Supply Chain Networks: Building robust, collaborative networks with suppliers and other stakeholders can enhance responsiveness and flexibility. Such networks can facilitate better communication, coordination, and resource sharing.

Maintenance, Repair, and Operations (MRO)

MRO activities are critical to the sustainment and operational readiness of naval vessels. Ensuring that ships and submarines are maintained to the highest standards is essential for their longevity and performance.

Challenges

1. Complex Maintenance Requirements: The maintenance of naval vessels involves intricate and time-consuming procedures, often requiring specialised skills and equipment.
2. Resource Constraints: Limited availability of skilled personnel, dry docks, and maintenance facilities can create bottlenecks in the MRO process.
3. Environmental and Regulatory Compliance: MRO activities must comply with stringent environmental regulations and safety standards, adding to the complexity and cost.

Opportunities

1. Digital Twins and IoT: Implementing digital twin technology and IoT can enhance MRO by providing real-time monitoring and diagnostics. Digital twins allow for virtual replicas of physical assets, enabling predictive maintenance and reducing downtime.
2. Remote Assistance and Augmented Reality: Using augmented reality (AR) and remote assistance technologies can help bridge the gap in specialised skills and knowledge. Experts can provide real-time guidance to maintenance crews, improving efficiency and accuracy.
3. Sustainable Practices: Adopting sustainable MRO practices, such as using environmentally friendly materials and processes, can reduce the environmental impact and ensure compliance with regulations.

Sustainment and Fleet Capability

Sustainment involves the continuous support and upkeep of naval vessels to ensure they remain operationally effective throughout their service life. This includes everything from routine maintenance to major overhauls and upgrades.

Challenges

1. Aging Fleet: As naval vessels age, they require more intensive and frequent maintenance, which can strain resources and budgets.
2. Technological Advancements: Keeping pace with rapid technological advancements is challenging. Upgrading existing vessels with new technologies can be complex and costly.
3. Supply Chain Resilience: Ensuring the resilience of the supply chain against disruptions, whether from geopolitical tensions, natural disasters, or other factors, is crucial for sustainment.

Opportunities

1. Lifecycle Management: Implementing comprehensive lifecycle management strategies can optimise the sustainment of naval vessels. This involves planning for the entire lifecycle from the outset, including acquisition, maintenance, upgrades, and decommissioning.
2. Modular Upgrades: Designing vessels with modular systems that can be easily upgraded can enhance fleet capability. This allows for the integration of new technologies without the need for extensive modifications.
3. Enhanced Supply Chain Resilience: Building a resilient supply chain through diversification, risk management, and robust logistics planning can mitigate the impact of disruptions. This includes developing local capabilities and reducing reliance on single-source suppliers.

AUKUS and the Need for Capability Uplift

The AUKUS partnership between Australia, the United Kingdom, and the United States represents a significant opportunity for Australia to enhance its naval capabilities. This partnership includes the acquisition of nuclear-powered submarines and the development of advanced technologies. However, realising these capabilities requires a substantial uplift in the Australian naval supply chain.

Challenges

1. Nuclear Expertise and Infrastructure: Developing the necessary expertise and infrastructure to support nuclear-powered submarines is a major challenge. This includes training personnel, establishing maintenance facilities, and ensuring regulatory compliance.
2. Integration of Advanced Technologies: Incorporating advanced technologies such as AI, cyber warfare capabilities, and unmanned systems into the naval fleet requires significant investment and adaptation.
3. Industrial Base Development: Building a robust industrial base capable of supporting the production, maintenance, and sustainment of advanced naval vessels is essential. This includes fostering innovation, supporting local industries, and developing a skilled workforce.

Opportunities

1. Strategic Partnerships and Collaboration: Leveraging strategic partnerships with the UK and the US can facilitate knowledge transfer, joint research and development, and collaborative training programs. This can accelerate the development of the necessary capabilities and infrastructure.
2. Investment in Education and Training: Investing in education and training programs to develop the required skills and expertise is critical. This includes specialised training for nuclear technologies, advanced manufacturing, and cybersecurity.
3. Innovation and Technology Adoption: Embracing innovation and adopting cutting-edge technologies can enhance fleet capability and operational readiness. This includes developing indigenous capabilities in areas such as AI, robotics, and advanced materials.
4. Economic and Industrial Growth: The AUKUS partnership presents an opportunity for economic and industrial growth in Australia. By developing a strong industrial base and fostering innovation, Australia can create high-value jobs and drive economic development.

The challenges and opportunities in naval supply chains are multifaceted and require a comprehensive approach to address. From managing spare parts and optimising inventory to enhancing MRO and sustainment practices, each aspect of the supply chain plays a critical role in maintaining fleet capability. In the context of the AUKUS partnership, Australia must undertake a significant uplift in its naval supply chain capabilities to meet new requirements and leverage the opportunities presented by this strategic alliance.

By embracing advanced technologies, fostering strategic partnerships, and investing in education and training, Australia can build a resilient and effective naval supply chain. This will not only enhance its naval capabilities but also contribute to regional security and economic stability. The road ahead is challenging, but with the right strategies and investments, Australia can rise to the occasion and secure its maritime interests for the future.

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