MRO - Maintenance, Repair & Operations
MRO is a solution for integrated management of maintenance and operations materials on the manufacturing floor. Core capabilities include employee/department association, VED/ABC/FSN multi-dimensional classification, catalog purchasing, blanket purchase agreements (BPA), ROP auto-replenishment, receiving inspection, inventory management, issue control, departmental budget management, supplier evaluation, obsolete inventory disposition and standardization, equipment spare parts BOM, PPE issuance, and MSDS management. S-Tier extensions add repair shop orders, rotable management, warranty claims, shelf life tracking, kit management, RTV returns, inter-site transfers, and demand forecasting. The solution integrates with the EAM solution via loose coupling for equipment master and work orders, providing unified maintenance material management.
Solution Scale
| Category | Count | Description |
|---|---|---|
| Tables | 39 | 37 domain + 2 system |
| Relationships | 98+ | 55 domain + 31 SYSTEM_REF + 12 S-Tier cross |
| Workflows | 9 | Purchase request, receiving inspection, issue request, budget management, obsolete inventory/standardization, repair shop, warranty claims, RTV returns, inter-site transfers |
| Management Screens | 25+ | List views / dashboards |
| POP Screens | 5 | Shop-floor touch-optimized |
| Dashboard Widgets | 12 | KPI cards, line charts, pie charts, bar charts, gauge charts, stat cards |
Core Areas
Document Structure
| Document | Contents | Tables |
|---|---|---|
| Item Management | Item master registration, classification hierarchy, VED/ABC/FSN classification grades, catalog management | 5 |
| Purchasing & Procurement | Purchase requests, purchase orders, blanket agreements (BPA), supplier management and evaluation | 7 |
| Inventory & Logistics | Receiving inspection, inventory management, stock locations, stock transactions, issue control, safety stock/ROP | 9 |
| Budget & Safety | Budget management, cost centers, obsolete inventory disposition, standardization, equipment spare parts BOM, PPE issuance, MSDS | 8 |
| S-Tier Extensions | Repair shop, rotable parts, warranty claims, shelf life tracking, kit management, RTV returns, inter-site transfers, demand forecasting | 10 |
| POP Terminal | Shop-floor touch-optimized screens (material issue, receiving confirmation, inventory lookup, PPE issuance, Tool Crib) | 5 screens |
Menu Groups
| Menu Group | Key Screens |
|---|---|
| Item Management | MRO Item Master, Item Categories, Classification Grades, Equipment Spare Parts BOM |
| Purchasing / Procurement | Catalog Management, Catalog Items, Purchase Requests, Purchase Orders, PO Line Items, Blanket Agreement Management, Supplier Management, Supplier Evaluation |
| Receiving / Inspection | Goods Receipt Management, Receiving Inspection |
| Inventory / Warehouse | Inventory Status, Stock Locations, Stock Transactions, Reorder Point Management, Obsolete Inventory Management |
| Issue / Consumption | Issue Requests, Consumption Records |
| Budget / Costing | Budget Management, Budget Actuals, Cost Centers, Standardization Projects |
| Safety / PPE | PPE Assignment Management, MSDS Registry |
| MRO POP | Material Issue POP, Receiving Confirmation POP, Inventory Lookup POP, PPE Issuance POP, Tool Crib POP |
Workflow List
| Workflow | Nodes | Trigger | Core Process |
|---|---|---|---|
| Purchase Request (WF1) | ~15 | Purchase request created | Registration -> Type determination -> [Catalog/Standard/Emergency] -> Amount check -> [Small auto-approve/Large approval] -> PO creation -> Notification -> Complete |
| Receiving Inspection (WF2) | ~12 | Goods receipt received | Receipt -> Grade determination -> [Full/Sampling/Skip] -> Result judgment -> [Pass -> Update inventory / Fail -> Return] -> Notification -> Complete |
| Issue Request (WF3) | ~14 | Issue request created | Receipt -> Grade determination -> [C-grade auto/AB-grade approval] -> Stock check -> [Sufficient -> Issue / Insufficient -> Emergency PR] -> Notification -> Complete |
| Budget Management (WF4) | ~12 | Budget formulation | Formulation -> Approval -> Monitoring -> Alert check -> [Normal/Warning/Critical/Exceeded] -> Settlement -> Notification -> Complete |
| Obsolete Inventory / Standardization (WF5) | ~11 | Obsolete inventory identified | Identification -> Review -> Disposition judgment -> [Transfer/Return/Sell/Dispose] -> Execute -> Feedback -> Notification -> Complete |
| Repair Shop (WF6) | ~14 | Repair order received | Receipt -> Diagnosis/Inspection -> Repair type determination -> [Overhaul/Repair/Modification] -> Testing -> [Pass -> Ship / Fail -> Re-repair] -> Notification -> Close |
| Warranty Claims (WF7) | ~14 | Claim registered | Defect found -> Warranty check -> [Under warranty/Out of warranty] -> Claim registration -> Approval -> Vendor submission -> Vendor response -> [Approved/Rejected/Negotiate] -> Settlement -> Close |
| RTV Returns (WF8) | ~12 | RTV registered | Registration -> Return reason determination -> Approval -> Contact vendor -> Ship -> [Credit/Exchange/Repair] -> Settlement -> Notification -> Close |
| Inter-Site Transfer (WF9) | ~12 | Transfer request created | Request -> Approval -> Issue -> Transport -> Receiving confirmation -> Inventory update -> Notification -> Close |
Dashboard Widgets
| Widget | Type | Data Source | Description |
|---|---|---|---|
| Inventory Value | Stat Card | mro_inventory | Total value of all MRO inventory |
| Inventory Turnover | Gauge Chart | mro_inventory | Inventory turnover rate indicator |
| VED Inventory Distribution | Bar Chart | mro_item_classification | Inventory distribution by V/E/D grade |
| Stockout Rate Trend | Line Chart | mro_inventory | Monthly stockout rate trend |
| Emergency Purchase Ratio | Gauge Chart | mro_purchase_requests | Emergency purchase ratio indicator |
| Consumption by Department | Bar Chart | mro_consumption_records | MRO material consumption cost by department |
| Budget vs. Actuals | Bar Chart | mro_budget_actuals | Budget versus actuals comparison |
| On-Time Delivery Rate | Pie Chart | mro_supplier_evaluations | Supplier on-time delivery rate |
| Obsolete Inventory Ratio | Pie Chart | mro_obsolete_items | Obsolete inventory ratio by disposition type |
| PPE Replacement Due | Stat Card | mro_ppe_assignments | Number of PPE items due for replacement |
| Expiring Soon | Stat Card | mro_inventory | Number of items approaching expiration |
| Safety Stock Alert | Stat Card | mro_reorder_points | Number of items below safety stock level |
Cross-Solution Integration
| Integration Target | Integration Details | Reference Method |
|---|---|---|
| EAM | Equipment master, work orders via loose coupling | mro_equipment_spare_bom.equipment_code -> EAM equipment code |
| EAM | MRO inventory deduction when parts are used in EAM PM/BM | pm_parts_used.item_id -> mro_item_master |
EAM Integration
The MRO solution serves as the SSOT (Single Source of Truth) for maintenance materials within the EAM solution. The EAM solution declares MRO as a required dependency via requiredSolutions: ['mro'], making mro_item_master the single source of truth for all maintenance materials. Equipment spare parts BOM is managed through mro_equipment_spare_bom, and inventory is automatically deducted when MRO materials are consumed through EAM work orders.