Logistics/Distribution

MRO (Maintenance, Repair & Operations)

Unifies demand planning, procurement, and inventory management for all indirect materials that indirectly support production activities.

ISO 9001 (Quality Management System)

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Are you facing these challenges?

1. You cannot accurately track how much is spent on indirect materials

Direct materials are managed by BOM, but indirect materials (maintenance parts, consumables, safety protective equipment) are purchased individually by each department, and the total spending is not even accurately aggregated. The same material is repeatedly purchased from different suppliers at different prices by different departments.

2. Critical maintenance parts are unavailable when needed, while dead stock keeps accumulating

Equipment downtime occurs because urgently needed maintenance parts are out of stock. Meanwhile, materials purchased in bulk that go unused pile up in the warehouse as dead stock. There is no way to forecast which materials are needed and in what quantities.

3. Procurement lead time from purchase request to issue is too long

When materials are needed on the shop floor, a purchase request must be submitted, approved, ordered, and then receipt awaited. Even urgent requests go through the same process, leading to extended wait times. Without ROP (Reorder Point)-based automatic ordering, you are always in reactive mode.

4. Part specifications are not standardized, leading to the same item managed under different names

The same bearing is registered under three names within the factory -- 'SKF 6205', 'SKF6205-2RS', '6205 Bearing' -- with separate inventory for each. Without specification consolidation, unnecessary inventory grows and finding compatible alternatives becomes difficult.

5. Shelf life management, receiving inspection, and warranty claims are not systematic

Shelf life management for chemicals, lubricants, adhesives, and similar materials is done manually. Receiving inspection criteria are unclear, and warranty claims for defective materials from suppliers are not processed in time, resulting in unrecovered costs.

Here is how we solve it

Make indirect material spending transparent and reduce costs

A VED/ABC/FSN 3-dimensional classification system analyzes material criticality, cost, and consumption velocity from multiple perspectives. Unlike most MRO systems that only support ABC classification, three viewpoints can be cross-analyzed.

VED Classification (Vital / Essential / Desirable): Classifies based on impact on equipment uptime. Vital materials maintain generous safety stock since shortages lead to line stops, while Desirable materials operate at minimum inventory.
ABC Classification: Pareto analysis by cost identifies the A-class materials that account for 80% of spending.
FSN Classification (Fast / Slow / Non-moving): Identifies dead stock (Non-moving) candidates early based on consumption velocity. Materials that have not moved for extended periods are identified for disposition or purchase discontinuation.

Cross-referencing these three classifications reveals, for example, "high-cost but rarely used (A+Non-moving) materials," providing starting points for inventory optimization.

Reduce unnecessary inventory through specification standardization

The Standardization Project feature enables consolidation of identical/similar material specifications.

Before/After Comparison: Quantitatively track pre-consolidation item count, post-consolidation item count, estimated savings, and actual savings.
Alternative Material Management: Register compatible materials so that when original materials are out of stock, alternatives can be found immediately.
Catalog Management: An approved material catalog ensures shop-floor workers select from standardized items, preventing uncontrolled purchases of non-standard materials.

Shorten procurement lead time with automatic ordering

5 purchase request types (ROP auto, PM-linked, emergency maintenance, manual, catalog) optimize procurement paths for different situations.

ROP Auto-Ordering: Purchase requests are automatically generated when inventory falls below the reorder point (ROP). No need for personnel to check stock levels daily.
PM-Linked Ordering: When preventive maintenance (PM) work is scheduled, required materials (PM kits) are automatically secured in advance. This prevents maintenance being postponed due to material unavailability.
Emergency Maintenance (BM) Ordering: A simplified process is separately defined for urgent material procurement during equipment failures.
Blanket Contract-Based Ordering: Register blanket contracts with key suppliers and place simplified orders based on contract pricing. This eliminates the inefficiency of negotiating prices for every individual purchase.

Systematically manage repair operations

Repair Shop Order management covers the full lifecycle.

Full Repair Lifecycle Tracking: 24 attributes record repair history including defect description, root cause analysis, repair details, test results, and quality grade.
Re-Repair Loop: If post-repair inspection fails, re-repair is ordered. A maximum re-repair count prevents infinite loops, and when the limit is exceeded, the item automatically transitions to condemned (CONDEMNED) status.
Rotable Pool Management: Track operating hours, cycle count, remaining life, and life limits for repairable components (rotables). Alerts are triggered in advance when overhaul (OH) intervals are approaching.

Systematic shelf life, receiving inspection, and warranty claim management

Shelf Life Management: 23 attributes manage shelf life including FEFO (First Expired First Out) priority issuance, re-testing, expiry extension approval, and storage condition management. Pre-expiry alerts reduce disposal losses.
AQL Sampling Inspection: Establish sampling inspection plans based on ISO 2859-1. General inspection levels (I/II/III) and special inspection (S1-S4), accept/reject numbers, and inspection severity switching rules (normal-tightened-reduced) are fully implemented.
Warranty Claims: Manage the full lifecycle from warranty coverage registration through claim submission, processing, and settlement. When receiving inspection fails, the return to vendor (RTV) process and warranty claim are automatically linked.
SDS Management: Register GHS pictograms, hazard classifications, and storage requirements to systematize safety management standards for hazardous materials.

Global standards this solution follows

ISO 2859-1 -- AQL Sampling Inspection Standard

Why does this standard matter?

ISO 2859-1 is the international standard for statistically determining "how many items to inspect from a lot and how many or fewer defects constitute acceptance" during receiving inspection. Without this standard, inspection criteria depend on individual judgment, leading to repeated over-inspection (wasted labor) or under-inspection (defective material intake). It also provides objective evidence in quality disputes with suppliers.

How is it applied in VEXPLOR?

ISO 2859-1 Requirement	What It Means for Your Operations	VEXPLOR Approach
Inspection Level Setting (I/II/III, S1-S4)	Apply different inspection intensity based on material criticality and past quality history	General inspection 3 levels + special inspection 4 levels selectable in AQL sampling plans
Ac/Re Decision Numbers	Automated sample size and accept/reject criteria based on lot size, preventing "inspecting a few by feel"	Automatic calculation of acceptance number (Ac) and rejection number (Re) by lot size
Inspection Severity Switching Rules	Inspection automatically becomes reduced for good-quality suppliers and tightened for suppliers with frequent defects	Normal-tightened-reduced 3-level switching rules fully implemented
Inspection Result Records	Results accumulate as history, providing objective evidence for supplier evaluation and warranty claims	Automatic inspection history recording, supplier scorecard integration

ISO 55000 -- Asset Management Standard

Why does this standard matter?

ISO 55000 is the international standard for systematically managing an organization's physical assets (equipment, parts, tools) across their entire lifecycle. The core principle is that assets must be managed not just "when purchased" but through "operation-maintenance-replacement-disposal" -- managing total lifecycle cost. In manufacturing, cost optimization of equipment and maintenance parts is systematically achieved when based on the ISO 55000 framework.

How is it applied in VEXPLOR?

ISO 55000 Requirement	What It Means for Your Operations	VEXPLOR Approach
Asset Lifecycle Management	Track operating hours, cycle count, and remaining life of rotable components to predict replacement timing	mro_rotable_pool (26 columns) -- life limits, OH cycles, remaining_life_pct auto-calculated
Preventive Maintenance Planning	Pre-secure materials needed for maintenance work to ensure planned maintenance effectiveness	PM kit definitions + EAM integration, PM-linked automatic purchase requests
Cost Optimization	Track maintenance material costs by cost center and reduce unnecessary spending through specification consolidation	Budget planning/actuals tracking, standardization project savings quantitative management
Risk-Based Decision Making	Differentiate inventory strategy based on material criticality and consumption patterns	VED (criticality) / ABC (cost) / FSN (consumption velocity) 3-dimensional classification

MSG-3 -- Maintenance Program Development Standard

Why does this standard matter?

MSG-3 (Maintenance Steering Group-3) was originally created for aviation maintenance program development, but its core concepts of "on-condition maintenance" and "hard time maintenance" apply to equipment maintenance across all manufacturing. It provides systematic criteria for deciding whether to replace a part "unconditionally when time is up" or "check condition and replace when needed."

How is it applied in VEXPLOR?

MSG-3 Concept	What It Means for Your Operations	VEXPLOR Approach
On-Condition Maintenance	Check current part condition (remaining life, wear) to determine replacement timing	mro_rotable_pool remaining_life_pct auto-calculation, OH cycle management
Hard Time Limits	Replace when operating hours or cycles reach limits regardless of condition	life_limit_hours/cycles tracking, pre-alerts on limit approach
Maintenance Program Development	Define which parts to inspect/replace at what intervals per equipment	PM kits (mro_kit_definitions) support maintenance program concepts
Reliability-Centered Maintenance (RCM)	Analyze failure data to continuously improve maintenance strategies	6 demand forecasting methods for consumption pattern analysis; dedicated FMEA/RCM module planned for future expansion

EASA Part 145 / FAA AC 43-9C -- Maintenance Organization Certification Standards (Reference)

Why does this standard matter?

EASA Part 145 and FAA AC 43-9C are aviation maintenance organization certification standards, but requirements for repair record management, traceability, warranty management, and quality inspection serve as quality system benchmarks for general industrial equipment MRO as well.

How is it applied in VEXPLOR?

Regulatory Requirement	What It Means for Your Operations	VEXPLOR Approach
Repair/Modification Records	All repair work defects, causes, actions, and results must be systematically recorded	Repair shop orders with 24 columns (defect description, root cause, test results, quality grade)
Traceability	Parts must be traceable by serial number, lot number, and batch number	S/N tracking (rotable_pool + repair_shop_orders), shelf_life_tracking
Warranty/Claims	Warranty claims for defective parts from suppliers must be systematically managed	warranty_coverage + warranty_claims full lifecycle management
Shelf Life Management	Chemicals, lubricants, and similar shelf-life materials must be managed by FEFO principle	shelf_life_tracking with 23 columns, FEFO priority, re-testing, expiry extension approval
Rejection Processing	Receiving-rejected material returns and dispositions must be systematic	WF2 (return) + WF8 (RTV) workflows, automatic warranty claim linkage

VEXPLOR MRO focuses on general industrial equipment MRO. Aviation industry-specific standards (ATA iSpec 2200 Chapter system, Airworthiness Directives AD/SB) are currently not supported, which is an intentional design choice for a general-purpose MRO solution. An Aviation MRO Industry Pack is included in the long-term roadmap.

What sets it apart from existing systems

VED/ABC/FSN 3-Dimensional Classification

Most MRO systems only provide ABC classification. VEXPLOR MRO supports VED (criticality), ABC (cost), and FSN (consumption velocity) 3-dimensional classification for higher precision in inventory optimization.

For example, even among the same A-class (high-cost) materials, management strategy differs by VED classification:

A+Vital: Safety stock is mandatory (critical to equipment uptime)
A+Desirable: Purchase at point of need (alternatives available)

5 Purchase Request Types

ROP auto, PM-linked, emergency maintenance, manual, catalog -- 5 procurement paths for the diverse procurement situations in real factories. This resolves the inefficiency of existing systems where "all purchase requests go through the same process."

Re-Repair Loop with Condemnation Decision

The re-repair loop for repair operations is embedded in the workflow. When maximum re-repair count is exceeded, automatic transition to condemned status occurs. This accurately reflects real repair shop operating logic, systematizing the criteria for repairable vs. non-repairable decisions.

Consignment Inventory Management

Supports the consignment inventory (VMI) model where supplier-owned materials are stored in your warehouse with ownership transferring at the point of use. 2 ownership models and 4 settlement cycles enable flexible operations. This reduces inventory burden while securing material availability.

Standardization Project Quantitative Tracking

Quantitatively track specification consolidation effectiveness as "pre-consolidation item count vs. post-consolidation item count" and "estimated savings vs. actual savings." Specification consolidation becomes a measurable project, not just a slogan.

How does it compare to global solutions?

The functional scope of VEXPLOR MRO is compared with major global MRO/asset management solutions below. Since VEXPLOR MRO focuses on general industrial equipment MRO, aviation-specific features are marked separately.

SAP PM (Plant Maintenance) Feature Coverage

SAP PM Feature	VEXPLOR MRO Coverage	Coverage	What This Means for You
Functional Location	Inventory locations + EAM integration	70%	Basic location management is available; SAP PM-level functional location hierarchy is supplemented through EAM integration
Equipment Master	Spare parts BOM + EAM	60%	Equipment-specific spare parts management is supported; independent equipment master is managed in the EAM solution
Maintenance Plans	PM kit definitions	50%	Maintenance program concepts supported via PM kits; dedicated PM scheduler is planned
Work Orders	Repair shop orders	80%	Full repair lifecycle management (defect-repair-inspection-re-repair-condemnation)
Materials Management	28+ tables	90%	VED/ABC/FSN classification, ROP auto-ordering, catalog, blanket contracts, consignment inventory -- covers most core SAP MM material management features
Budget Control	Budget planning/actuals	85%	Cost center budget planning, actuals tracking, and overage warnings are supported
Reporting	15 dashboard widgets	75%	Core KPI monitoring is available but does not match SAP PM analytical report depth
Integration (FI/CO/MM)	Loose coupling (VARCHAR)	55%	EAM/ERP integration is possible but currently implemented via VARCHAR-based references; direct FK strengthening is planned

SAP PM Overall Coverage: approximately 71% -- Materials management area exceeds SAP PM; integration area is planned for future enhancement.

IFS Applications (Asset Management) Feature Coverage

IFS Feature	VEXPLOR MRO Coverage	Coverage	What This Means for You
Asset Register	Rotable pool management	70%	Repairable component life/cycle/remaining life tracking is available
Work Management	Repair operations + re-repair loop	80%	Repair management and re-repair decision logic are implemented at a practical level
Materials Planning	ROP + demand forecasting (6 methods) + safety stock	85%	6 demand forecasting methods and auto-ordering provide a high level of materials planning
Procurement	Catalog + blanket contracts + RTV	90%	5 purchase request types address diverse procurement scenarios
Service Contracts	Warranty management + blanket contracts	80%	Warranty lifecycle management and blanket contract-based procurement are supported
Mobile Workforce	5 POP screens	65%	Touch-optimized shop-floor screens provided; offline mode is not yet supported

IFS Overall Coverage: approximately 78% -- Strengths in procurement/materials area; mobile field operations planned for expansion.

Aviation MRO Solution Comparison (Reference)

VEXPLOR MRO is designed for general industrial equipment MRO. The aviation MRO Industry Pack is planned as a separate expansion. Comparison with aviation MRO solutions is provided for reference.

Comparison Target	Target Industry	VEXPLOR Coverage	What This Means for You
Ramco Aviation MRO	Aviation MRO	82% (excl. aviation-specific features)	Parts tracking, warranty claims, and shelf life areas are at aviation MRO level; ATA Chapter/Engineering Orders are not supported
AMOS	Aviation MRO	77% (excl. airworthiness features)	Materials management and quality management approach aviation levels; airworthiness management/Task Cards are not supported

Areas where VEXPLOR MRO can and cannot be applied in the aviation industry:

Aviation-applicable areas:

Rotable management (operating hours/cycles/life limit tracking) -- 80% applicable
Warranty claims (full vendor claim lifecycle) -- 90% applicable
Shelf life management (chemicals/sealant FEFO management) -- 95% applicable
AQL sampling inspection (component receiving inspection) -- 100% applicable

Aviation non-supported areas (to be addressed by Aviation MRO Industry Pack):

ATA Chapter classification system
Airworthiness Directive (AD) / Service Bulletin (SB) management
Back-to-Birth traceability (full history chain)
C/D Check Planning (heavy maintenance planning)

Overall Benchmark Summary

Comparison Solution	Target Industry	VEXPLOR Coverage	Core Strengths	Core Gaps
SAP PM	General Industrial	71%	Materials management (90%), Budget management (85%)	ERP integration (55%), PM scheduler (50%)
IFS Applications	Asset-Intensive Industry	78%	Procurement (90%), Materials planning (85%)	Mobile (65%), Asset register (70%)
Ramco Aviation	Aviation MRO	82% (excl. aviation)	Warranty/shelf life (90%)	ATA Chapter (0%), Engineering Order (0%)
AMOS	Aviation MRO	77% (excl. airworthiness)	Materials management (85%), Quality (75%)	Airworthiness (0%), Task Card (30%)

Transparently disclosed unsupported features

Features provided by global solutions but not currently supported in VEXPLOR MRO are explicitly listed.

Unsupported Feature	Related Global Solution	Response Plan
PM Scheduler (independent maintenance program management)	SAP PM, IFS	Basic coverage via EAM integration; dedicated scheduler planned (medium-term)
Technical Document Management (maintenance manuals, SOPs, technical drawings)	SAP PM, IFS	Only SDS supported; technical document tables planned (medium-term)
Direct ERP FK Integration	SAP PM	Currently loose coupling; direct FK reference strengthening planned (short-term)
MTBF/MTTR Analysis	SAP PM, IFS	EAM integration or dedicated calculation module planned (medium-term)
Offline POP	IFS Mobile	Service Worker + IndexedDB-based offline mode planned (long-term)
Calibration Management	SAP PM	Measuring instrument calibration history table planned (medium-term)
Electronic Signatures (21 CFR Part 11)	SAP PM (GxP)	Workflow approvals available; electronic signature specification expansion planned (long-term)
ATA Chapter / Airworthiness Management	Ramco, AMOS	Included in long-term roadmap as Aviation MRO Industry Pack

Expected benefits after implementation

Indirect material cost visibility

VED/ABC/FSN classification and category-level spending analysis make it transparent how much is being spent on indirect materials and where cost reduction opportunities exist. Cost center budget planning and actuals tracking enable departmental cost control.

Dead stock reduction

FSN classification enables early identification of Non-moving materials; specification consolidation reduces duplicate inventory. Shelf life management also reduces expiry-driven disposal.

Procurement lead time reduction

ROP auto-ordering, PM-linked pre-procurement, and blanket contract-based simplified ordering reduce time to material availability. A separately defined emergency procurement process for equipment failures improves response speed.

Indirect improvement in equipment uptime

When the right maintenance parts are available at the right time, maintenance delays due to material unavailability decrease. This leads to indirect improvement in equipment uptime. Rotable life management also enhances the effectiveness of planned maintenance.

Quality cost recovery

AQL-based receiving inspection blocks defective material intake, and systematic warranty claim management recovers costs for defective materials from suppliers.

Audit traceability

All material transactions (receipt, issue, return, adjustment, disposal) are automatically recorded with performer and timestamp. Material movement history can be immediately evidenced during ISO certification audits or internal audits.

Budget control enhancement

Cost center budget planning, actuals tracking, and budget overrun warnings operate automatically. Departmental indirect material spending becomes transparent, with pre-warnings available before budget overruns.

Features for shop-floor operations

5 POP (Shop-Floor) Screens

Touch-optimized screens ready for immediate use in warehouses and maintenance shops are provided.

Material Issue/Return: Issue materials via barcode scan and return unused materials.
Receiving Inspection: Immediately verify quantity and quality of received materials on-site.
Inventory Count: Perform barcode scan-based cycle counts.
Tool Crib: Manage tool checkout and return.

4-Dimensional Supplier Evaluation

Suppliers are quantitatively evaluated across 4 dimensions: quality, delivery, price, and service. Evaluation results inform decisions on blanket contract renewal, volume adjustments, and other actions.

11 Automated Workflows

Core processes including purchase request approval, receiving inspection, return processing, repair work progression, RTV (Return to Vendor), warranty claims, and safety equipment issuance are automated through workflows. Each workflow includes 8 approval nodes with electronic approval to ensure decision-making transparency.

15 Dashboard Widgets

Core MRO operational indicators -- inventory status, budget vs. actuals, purchase request status, demand forecasts, supplier evaluation -- are visible at a glance on dashboards.

6 Demand Forecasting Methods

6 demand forecasting methods are available: moving average, exponential smoothing, regression analysis, seasonal, consumption-based, and ML prediction. Select the forecasting method appropriate for each material's characteristics to maintain optimal inventory levels.

Cross-solution integration

VEXPLOR MRO is not a standalone indirect material management system; it integrates into your enterprise's equipment management and production operations framework.

Linked Solution	Integration Details
EAM (Equipment Management)	Equipment-specific spare parts BOM, PM work linkage, failure history reference
ERP	Item master, purchase request/order, accounts payable, financial integration
WMS	Indirect material receiving/issuing, storage locations, inventory counts
QMS	Receiving quality inspection, nonconformance handling, corrective actions

Current cross-solution integration is implemented via loose coupling (VARCHAR-based references), with plans to strengthen to direct FK reference in the future.

Industry suitability

VEXPLOR MRO is designed for general industrial equipment MRO.

Industry	Suitability Level	Key Strengths	Additional Considerations
Automotive Parts Manufacturing	High	VED/FSN classification, PM linkage, Tool Crib	MTBF/MTTR integration expansion needed
General Manufacturing	High	Full area coverage, ROP auto-ordering, AQL	Seasonal demand auto-learning expansion needed
Chemical/Refining	Moderate	Shelf life management, SDS, hazardous material classification	Calibration management addition needed
Food Manufacturing	Moderate	FEFO, batch tracking, AQL	GMP regulation expansion needed
Aviation MRO	Basic	Rotable management, S/N tracking, warranty claims	ATA Chapter, AD/SB management separately needed

Currently unsupported areas and response plans

Unsupported Area	Description	Response Plan
PM Scheduler	Independent maintenance program management, automatic maintenance schedule generation	Basic coverage via EAM integration; dedicated scheduler planned
Technical Document Management	Maintenance manuals, SOPs, technical drawings management	Only SDS supported; technical document tables planned
MTBF/MTTR Analysis	Equipment reliability analysis metrics auto-calculation	EAM integration or dedicated calculation module planned
Calibration Management	Measuring instrument calibration history and cycle management	Dedicated table planned
Electronic Signatures (21 CFR Part 11)	Electronic signature for pharmaceutical/medical device regulatory compliance	Workflow approvals available; electronic signature specification expansion planned
Offline POP	Shop-floor operations in unstable network environments	Service Worker + IndexedDB-based offline mode planned
Aviation MRO Industry Pack	ATA Chapter, AD/SB management, Task Card	Included in long-term roadmap

Safety Protective Equipment (PPE) Management

The MRO solution includes PPE issuance and training linkage features. A built-in process verifies training completion for the relevant protective equipment at the time of PPE issuance, supporting compliance with occupational safety and health regulations.

Real-world usage scenarios

Scenario 1: ROP auto-ordering to prevent material shortages

Cutting fluid inventory for the CNC machining line drops below the reorder point (ROP). The system automatically generates a purchase request, and the order is placed with the supplier registered under a blanket contract. The maintenance team does not need to check stock levels daily -- materials are secured when needed.

Scenario 2: PM-linked material pre-procurement

A press mold replacement PM scheduled for next week requires specific materials (hydraulic seals, bolts, grease) defined in a PM kit. When the work schedule is confirmed, available inventory for kit materials is automatically checked, and purchase requests are generated for any shortages. This reduces instances of maintenance being postponed due to material unavailability on the work day.

Scenario 3: Dead stock cleanup

FSN classification results identify 47 Non-moving items with zero consumption over 2 years. Of these, 32 items classified as VED Desirable (non-essential) are reviewed for disposition. In conjunction with the standardization project, 8 additional items are identified as consolidatable into alternatives, and inventory for a total of 40 items is cleared to recover warehouse space and capital.

Scenario 4: Repair operations and re-repair decision

A motor pump repair order is received. Disassembly inspection reveals impeller wear, so the impeller is replaced and a trial run inspection is conducted. When vibration values exceed standards and fail inspection, the re-repair loop activates. After additional bearing replacement and re-inspection pass, the unit returns to the rotable pool. If the maximum re-repair count (3) is exceeded, automatic transition to condemned (CONDEMNED) status triggers a new part procurement process.

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