ABC Analysis of Maintenance Spares: A practical guide to smarter spare-parts decisions
About this ebook
A practical guide to smarter spare-parts decisions
Maintenance spares are more than boxes on a shelf. They are part of a plant’s reliability system, working capital, risk control, and ability to deliver production safely. ABC analysis offers a simple way to focus management attention on the items that represent the greatest annual consumption value.
This book explains how to collect reliable data, calculate annual usage value, classify items into A, B, and C groups, combine value analysis with equipment criticality, set review rules, and build a disciplined process across maintenance, stores, purchasing, finance, and operations.
Examples are illustrative rather than plant-specific. The book also highlights limitations: low-cost parts can stop a critical machine, high-value parts may have long lead times, and historical consumption alone cannot predict every failure. For that reason, ABC analysis should be combined with criticality, lead-time, failure-mode, and obsolescence reviews.
Readers can use the practical checklists and sample formats as starting points. Adapt every policy to site conditions, OEM recommendations, safety requirements, and approved procurement rules.
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About the author
ABOUT THE AUTHOR
Chetan Singh Chauhan
Chetan Singh Chauhan works in industrial maintenance and brings practical interest in electrical equipment, preventive maintenance, spare-parts planning, and operational improvement. This book is written from the perspective that good maintenance stores practices should support safe operation, faster restoration, and responsible use of working capital.
The author’s approach is practical: establish trustworthy data, define clear ownership, review exceptions, and make decisions with maintenance, procurement, stores, and finance working together. The examples are designed to help readers start conversations and build repeatable systems rather than rely on assumptions.
This short professional biography is intended for the book edition. Readers should verify any additional qualifications, employment details, or institutional affiliations before adding them to a commercial publication.
