Spare Parts Management – Why a Smart Spare Parts Strategy Drastically Reduces Downtime
Spare Parts Management – Why a Smart Spare Parts Strategy Drastically Reduces Downtime
Imagine this:
An extrusion line is running at full capacity. Suddenly, a small but critical component fails.
The spare part isn’t in stock. The machine stops. Production is delayed – and every hour of downtime costs real money.
This happens more often than you might think. Not because the technology is bad, but because spare parts management is often underestimated.
Why spare parts management is so critical:
- Unplanned downtime is the most expensive kind of downtime – planned maintenance can be scheduled, but sudden failures cannot.
- Stocking based on intuition either leads to high costs (too many parts in inventory) or shortages when they are urgently needed.
- Delivery times for specialized components can take weeks – time production cannot afford to lose.
Benefits of a smart spare parts strategy:
- Identify critical parts – not every component needs to be in stock, but the truly essential ones must be.
- Optimize inventory – a small, well-structured inventory beats a large, unorganized stock.
- Create transparent processes – digital tools or simple checklists help maintain control.
- Leverage partnerships – a service partner with fast spare parts delivery often saves more than a company could by holding parts itself.
Real-world example:
One of our clients struggled for years with downtime caused by missing spare parts. After we collaborated to create a spare parts list and set up a small but targeted inventory, we were able to reduce downtime by over 60%.
This shows: A smart spare parts strategy isn’t a cost center – it’s a profit driver.
My tip for extrusion line operators:
Ask yourself whether your spare parts management is truly practical – or if you’re just hoping for luck the next time a component fails.
