Harnessing condition-based maintenance methodologies and technology to enable maintenance efficiency and sustainability

August 29, 2024

Asset Management and Maintenance by James Allt-Graham

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.

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.

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.

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.  

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!

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

James Allt-Graham
Partner

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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Asset Management & Supply Chain Management for Universities

Universities have a vast array of assets that they need to manage effectively, including buildings, equipment and technology.

Asset management and supply chain management are two critical components of any organisation's success, including universities.

Universities have a vast array of assets that they need to manage effectively, including buildings, equipment, technology, and personnel. They also need to manage their supply chain to ensure that they have the resources they need to operate efficiently. These requirements across assets and supply chain can vary significantly by Faculty.

In this blog article, we will explore the intersection of asset management and supply chain management for universities and discuss some best practices for managing both effectively.

Asset Management for Universities

Asset management for universities is the process of tracking and maintaining the physical assets of the institution. This includes everything from buildings and land to equipment, furniture, and technology. Effective asset management is essential to ensure that universities have the resources they need to provide high-quality education and research.

One of the key challenges of asset management for universities is tracking the location and condition of assets. Universities often have multiple campuses and departments, which makes it difficult to keep track of where assets are located and who is using them. Additionally, assets can wear out or become obsolete, which requires universities to plan for replacement or repair.

To overcome these challenges, universities should implement an asset management system that includes:

  1. Asset tracking: Universities should use a system that allows them to track the location and condition of assets in real-time. This can be accomplished using barcodes, RFID tags, or GPS technology.
  2. Maintenance schedules: Universities should have a maintenance schedule for each asset to ensure that it is kept in good condition and replaced when necessary.
  3. Budget planning: Universities should plan for the replacement or repair of assets in their budget to ensure that they have the resources they need when assets reach the end of their life.

Supply Chain Management for Universities

Supply chain management for universities is the process of managing the flow of goods and services from suppliers to the institution. This includes everything from purchasing office supplies to contracting for construction projects. Effective supply chain management is essential to ensure that universities have the resources they need to operate efficiently.

One of the key challenges of supply chain management for universities is managing multiple suppliers and contracts. Universities often have a large number of suppliers, which makes it difficult to manage contracts and ensure that they are getting the best value for their money.

To overcome these challenges, universities should implement a supply chain management system that includes:

  1. Supplier management: Universities should have a system for managing their suppliers, including contracts, performance metrics, and communication protocols.
  2. Budget planning: Universities should plan for their supply chain needs in their budget to ensure that they have the resources they need to operate efficiently.
  3. Procurement policies: Universities should have clear procurement policies that outline the process for purchasing goods and services and ensure compliance with regulations and ethical standards.

The Intersection of Asset Management and Supply Chain Management for Universities

The intersection of asset management and supply chain management for universities is where these two processes come together. Effective asset management is essential to ensure that universities have the resources they need to operate efficiently, and effective supply chain management is essential to ensure that they have the resources they need to maintain their assets.

To optimise the intersection of asset management and supply chain management, universities should:

  1. Integrate asset management and supply chain management systems: Universities should integrate their asset management and supply chain management systems to ensure that they are working together effectively.
  2. Plan for asset replacement and procurement: Universities should plan for the replacement of assets in their procurement policies to ensure that they have the resources they need to replace assets when necessary.
  3. Monitor performance metrics: Universities should monitor performance metrics for both asset management and supply chain management to ensure that they are meeting their goals and making continuous improvements.

Asset management and supply chain management are critical components of any organisation's success, including universities. By implementing effective systems and best practices, universities can ensure that they have the resources they need to provide high-quality education and research for their students and faculty. Integration of asset management and supply chain management systems, planning for asset replacement and procurement, and monitoring performance metrics are essential for universities to optimise the intersection of asset management and supply chain management. By doing so, universities can operate more efficiently, reduce costs, and ensure that they have the resources they need to continue their mission of educating the next generation of leaders.

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

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Optimising Your Automotive Parts Supply Chain: Strategies for Enhanced Efficiency and Competitive Advantage

Explore key strategies to enhance your automotive parts supply chain performance, reduce lead times, manage inventory efficiently, and see how Trace Consultants can guide your transformation.

Optimising Your Automotive Parts Supply Chain: Strategies for Enhanced Efficiency and Competitive Advantage

Australia and New Zealand's automotive sectors are among the most demanding and complex environments for effective supply chain management. With vehicles constantly evolving in complexity and consumer expectations around rapid repairs and service responsiveness higher than ever, supply chains managing automotive parts are under pressure to perform reliably and cost-effectively.

In this article, we'll explore the critical strategies and best practices to optimise automotive parts supply chains, focusing on how organisations can significantly enhance service delivery, reduce operating costs, and manage inventory more efficiently. We’ll also highlight how Trace Consultants can support your organisation in transforming supply chain operations to achieve lasting competitive advantages.

Why Automotive Parts Supply Chain Efficiency Matters

The automotive industry is incredibly competitive, with efficiency in parts supply chains often determining customer satisfaction and financial performance. Delays or inaccuracies in parts availability can lead to prolonged vehicle downtime, impacting customer satisfaction, dealership profitability, and overall business reputation.

For automotive organisations, achieving excellence in their parts supply chain can mean:

  • Reduced downtime and improved service responsiveness
  • Efficient inventory management and reduced holding costs
  • Increased profitability through better purchasing strategies
  • Stronger relationships with distributors and manufacturers

To achieve these outcomes, automotive organisations must proactively optimise their supply chain practices. Here's how:

1. Demand Forecasting and Inventory Optimisation

Effective demand forecasting is foundational to any high-performing automotive parts supply chain. Accurate forecasting ensures the right parts are available at the right time, significantly reducing downtime and improving customer experience.

Automotive parts demand can be highly variable and influenced by seasonality, new model launches, recalls, or emerging technologies (such as electric vehicles). Leveraging advanced forecasting tools and predictive analytics can improve accuracy and responsiveness significantly.

How Trace Consultants Can Help:

Trace Consultants offers expert guidance in implementing advanced forecasting solutions tailored for automotive parts distributors and dealerships. Our team helps you identify appropriate forecasting models, integrate AI-driven predictive analytics, and customise systems to suit your specific requirements, ensuring improved demand visibility and reduced forecasting error.

Optimising Inventory Management

Efficient inventory management is critical, especially considering the complexity of managing thousands of automotive SKUs. Optimised inventory management helps balance cost efficiencies with high availability, preventing both stockouts and excessive inventory holding.

Effective inventory management strategies include:

  • Inventory Optimisation Tools: Implementing advanced systems to maintain optimal stock levels.
  • Demand Segmentation: Categorising products based on demand frequency and criticality.
  • Vendor-Managed Inventory (VMI): Improving alignment and transparency with suppliers to manage inventory collaboratively.
  • Inventory Rationalisation: Reducing slow-moving parts and obsolete stock, freeing capital, and improving warehouse efficiency.

How Trace Consultants Can Help:

Trace Consultants specialises in implementing practical inventory optimisation solutions. We support automotive organisations in selecting and deploying sophisticated inventory systems, combined with data-driven strategies to streamline inventory management.

Enhancing Supply Chain Visibility

Real-time visibility across the automotive supply chain is vital. Improved visibility enables proactive decision-making, faster response to disruptions, and reduced risks associated with unpredictable events.

Enhanced visibility means being able to track parts from suppliers through distribution centres to dealerships or customers. Effective visibility also facilitates more proactive supplier management, ensuring responsiveness to fluctuations in demand or supply disruptions.

Visibility can be improved through:

  • Real-time tracking and monitoring systems
  • Integrated ERP and WMS solutions
  • Predictive analytics to foresee potential disruptions

How Trace Consultants Can Help:

Trace Consultants can assess and implement integrated technology solutions, such as cloud-based platforms and real-time analytics tools, providing clear end-to-end visibility to support timely and effective decision-making.

Strategic Procurement and Supplier Relationships

Procurement within automotive supply chains significantly impacts cost efficiencies and service reliability. Strategic procurement practices can help manage supplier risk, enhance purchasing leverage, and achieve economies of scale.

Key procurement strategies include:

  • Consolidation and rationalisation of suppliers
  • Leveraging scale in procurement
  • Strategic sourcing and contracting to improve cost-effectiveness
  • Establishing long-term partnerships to ensure supplier reliability and flexibility

How Trace Consultants Can Help:

Trace Consultants supports automotive clients in designing and executing robust procurement strategies, offering strategic sourcing reviews, spend analysis, and supplier benchmarking. Our approach ensures organisations gain the best commercial outcomes while maintaining supply chain resilience.

Streamlining Warehousing and Distribution

Efficient warehousing operations and a strategically designed distribution network ensure automotive parts arrive at the right location, on time, and in the most cost-effective manner.

Critical considerations include:

  • Warehouse Network Optimisation: Ensuring warehouses are strategically located to minimise transportation costs and maximise responsiveness.
  • Warehouse Automation: Investing in automation and robotics to increase accuracy, reduce labour costs, and improve efficiency.
  • Transport Management Systems (TMS): Optimising transport networks to enhance delivery performance and reduce transport costs.

How Trace Consultants Can Help:

Trace Consultants delivers comprehensive warehouse and transport optimisation solutions, working closely with automotive businesses to strategically design warehouse networks, enhance operational efficiency, and optimise logistics and transport strategies.

Mitigating Risks and Improving Compliance

Automotive supply chains are increasingly complex, making them vulnerable to risks, including supplier disruptions, regulatory compliance issues, and economic uncertainties.

Strategies for risk mitigation and compliance include:

  • Supply chain diversification
  • Regular benchmarking and performance monitoring
  • Compliance with sustainability and modern slavery regulations
  • Transparent supplier relationship management practices

How Trace Consultants Can Help:

Trace Consultants offers thorough benchmarking and auditing services to help automotive organisations identify, manage, and mitigate supply chain risks. We also assist organisations in achieving compliance with evolving regulations around sustainability, modern slavery, and ethical sourcing.

Implementing Robust Sales & Operations Planning (S&OP)

A robust Sales and Operations Planning (S&OP) process helps automotive businesses align demand forecasts, inventory levels, production schedules, and procurement activities.

Key elements include:

  • Collaborative demand planning
  • Integrated supply and demand forecasting
  • Scenario planning to manage disruptions proactively
  • Data-driven decision-making through advanced planning systems

How Trace Consultants Can Help:

Trace Consultants has extensive experience establishing effective S&OP frameworks, helping automotive organisations to better align operations, manage inventory effectively, and respond rapidly to changes in market conditions.

Why Partner with Trace Consultants?

Trace Consultants are supply chain specialists, deeply experienced in navigating the challenges faced by automotive organisations in Australia and New Zealand. Our approach combines advanced analytics, tailored solutions, and hands-on implementation support, helping your organisation achieve measurable improvements quickly.

Key services we offer include:

  • Comprehensive Supply Chain Diagnostics
  • Network Optimisation and Strategic Reviews
  • Inventory and Procurement Optimisation
  • Technology assessments and implementations (including Microsoft Power Apps and predictive analytics)
  • Change management and capability building to ensure sustainable improvements

By collaborating with Trace Consultants, automotive organisations benefit from strategic insights, actionable recommendations, and dedicated support, ensuring transformation projects deliver tangible, lasting results.

Ready to Optimise Your Automotive Supply Chain?

Optimising your automotive parts supply chain isn’t just about reducing costs—it's a strategic move to boost your competitive advantage, enhance customer satisfaction, and future-proof your operations.

How prepared is your organisation to transform your automotive parts supply chain? Reach out to Trace Consultants today to discuss how we can help you achieve supply chain excellence.

Asset Management and MRO
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AUKUS is a new dawn for MRO Supply Chains in Australia

Effective MRO is critical to ensure Australia’s Defence Capability and Preparedness.

Exploring the MRO Supply Chain for Defence Submarines: A Crucial Component for Operational Efficiency

The Maintenance, Repair, and Operations (MRO) supply chain encompasses the intricate processes that govern the procurement, inventory management, and delivery of goods and services for maintaining equipment, facilities, and other assets in optimal working condition. Defence submarines, as sophisticated underwater vessels, demand a well-orchestrated MRO supply chain to guarantee their longevity and effectiveness in executing critical missions. With further detail announced on the AUKUS partnership to introduce a nuclear submarine capability for Australia, let's examine the nuances of the MRO supply chain for defence submarines, its significance, challenges, and potential solutions for enhanced management.

The Indispensable Role of the MRO Supply Chain in Defence Submarines

Operating in highly demanding environments and performing tasks such as surveillance, intelligence gathering, and covert operations, defence submarines rely on a robust MRO supply chain for several reasons:

  1. Operational Readiness: An efficient MRO supply chain ensures submarines remain in prime condition, poised for deployment at a moment's notice. Regular maintenance and prompt repairs are crucial to maintaining mission-readiness.
  2. Cost Management: Streamlined MRO processes minimise the total cost of ownership (TCO) for defence submarines. By optimising MRO processes and sourcing appropriate components at opportune moments, defence organisations can reduce costs and bolster budget management.
  3. Safety: The MRO supply chain plays a pivotal role in safeguarding crew members aboard submarines. Routine maintenance and repairs can avert accidents and equipment malfunctions, thus protecting the lives of those onboard.

Navigating the Challenges in the MRO Supply Chain for Defence Submarines

Managing the MRO supply chain for defence submarines is a complex undertaking, laden with various challenges that warrant attention:

  1. Obsolescence: The rapid evolution of technology frequently renders submarine components obsolete, complicating the sourcing and management of replacement parts.
  2. Regulatory Compliance: Stringent regulations and standards govern defence submarines. Ensuring MRO processes and components adhere to these requirements is a demanding challenge that necessitates continuous vigilance.
  3. Global Sourcing: Procuring submarine components from global suppliers can introduce logistical challenges and delays, impacting the timely execution of MRO tasks.

Strategies for Enhanced MRO Supply Chain Management

To surmount these challenges and optimise the MRO supply chain for defence submarines, the following strategies can be adopted:

  1. Data Analytics and Predictive Maintenance: Harnessing data analytics enables defence organisations to better anticipate maintenance requirements and refine the MRO supply chain. Predictive maintenance facilitates the identification of potential issues before they escalate, allowing for prompt repairs and minimising downtime.
  2. Collaborative Planning: Cooperation among suppliers, manufacturers, and other supply chain stakeholders can address issues related to obsolescence, regulatory compliance, and global sourcing.
  3. Standardisation and Modularisation: Embracing standardised processes and modular designs can simplify MRO processes and reduce the number of unique components required for repairs, enhancing sourcing and management efficiency.
  4. Digital Transformation: Adopting digital technologies such as blockchain, the Internet of Things (IoT), and artificial intelligence (AI) can augment the visibility, efficiency, and security of the MRO supply chain.

The MRO supply chain is an essential component in guaranteeing the operational efficiency and readiness of defence submarines. By addressing inherent challenges and adopting effective strategies for superior management, defence organisations can sustain a high level of preparedness while ensuring the safety and cost-effectiveness of these vital underwater vessels.

AUKUS - a new dawn for MRO Supply Chains in Australia

The Virginia-class submarines – one of the two proposed in the AUKUS agreement – form the backbone of the United States Navy's attack submarine fleet, gradually replacing the older Los Angeles-class.

Whilst critical to maintain peace in the Asia-Pacific region, these submarines will be complex and costly to maintain. With a F-35 combat aircraft having in excess of 300,000 parts from 1,700 suppliers – it is not stretch to then assume a submarine of the size, scale and capabilities of the Virginia-class has well over 950,000 different parts and components, including complex machinery, electrical and electronic systems, pumps, valves, sensors, and many other types of equipment. With the US industrial supply chain behind the Virginia-class reportedly under strain, with parts wearing out sooner than expected and cannibilisation occuring across platforms, it will be crucial for Australian Defence planners and industry to invest in their MRO planning capability.

Planning service parts supply chains is a complex task that involves dealing with various challenges such as high-cost parts, long lead times, multiple sources for the same part, sporadic and low-volume part usage patterns, and the contrasting requirements and preferences of OEMs.

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