Enhancing Efficiency and Effectiveness in MRO Inventory Management Using Lean Six Sigma.

Effective Maintenance, Repair, and Operations (MRO) inventory management is vital for sustaining plant productivity and minimizing process downtime. Achieving efficiency in this area requires robust practices supported by continuous improvement methodologies. Lean Six Sigma (LSS) integrates Lean's focus on waste elimination--such as overstocking and delays--with Six Sigma's emphasis on reducing variability and errors, offering a powerful approach to process optimization. This study applies key LSS tools, including DMAIC, process mapping, Pareto analysis, value stream mapping, Kanban, and root cause analysis, to streamline MRO inventory management. The study proposes a unified LSS framework for continuous improvement in MRO inventory processes. The findings demonstrate that the framework significantly reduces order fulfillment times, material handling, and inventory costs, while enhancing customer service, operational efficiency, and process effectiveness. Additionally, it strengthens supply chain performance, improves plant productivity, and minimizes process downtime, delivering measurable advancements in maintenance efficiency and effectiveness. [ABSTRACT FROM AUTHOR]