Inventory & MRO Analyst

The Inventory & MRO Analyst is responsible for optimizing maintenance, repair, and operations (MRO) inventory to ensure maximum equipment uptime in a highly automated, multi-line food manufacturing facility. This role manages a multi-million-dollar repair and maintenance (R&M) budget, drives inventory accuracy, and ensures critical spare parts availability for continuous production in a USDA-regulated environment.The ideal candidate combines data analytics, maintenance planning, and inventory control expertise to reduce downtime, improve asset reliability, and control costsKey Responsibilities – Inventory & MRO AnalystStrategic MRO Inventory OptimizationDesign and continuously refine inventory segmentation strategy (critical spares vs. consumables vs. long-lead items vs. rarely used insurance spares).Perform criticality analysis (ABC + equipment criticality) to identify parts that directly impact production uptime.Build and maintain dynamic min/max and safety stock models using:Usage variabilitySupplier lead times (standard vs. expedited)Equipment failure patternsDrive risk-based stocking strategies:Zero-stock tolerance for uptime-critical componentsVendor-managed inventory (VMI) where viableLead SKU rationalization initiatives:Identify duplicates across OEMs or linesStandardize components across similar equipmentActively manage inventory lifecycle:Introduce new parts for new equipment or upgradesPhase out obsolete or end-of-life componentsDeep Maintenance & Reliability IntegrationTranslate maintenance strategies into inventory requirements:PM (Preventive Maintenance) kitsPdM (Predictive Maintenance) replacement profilesBreakdown/spare readiness modelsWork directly with Maintenance Planners to:Pre-stage parts for shutdowns, rebuilds, and changeoversBuild kitted jobs for faster wrench time executionAnalyze failure data (via CMMS) to:Identify chronic part failuresRecommend higher-spec or alternative componentsAdjust stocking levels based on real failure curvesSupport planned outage execution:Ensure all parts are available weeks in advanceCreate contingency plans for critical equipmentEmbed reliability concepts:MTBF (Mean Time Between Failure) alignment with stockingMTTR (Mean Time to Repair) reduction via parts readinessFinancial Ownership & R&M Cost ControlServe as the day-to-day steward of a multi-million-dollar R&M budget.Develop annual MRO spend forecasts by:Asset class (processing, packaging, automation)Maintenance strategy (PM/PdM/reactive)Conduct monthly variance analysis:Identify cost spikes by line, failure type, or supplierPartner with maintenance to correct cost driversDrive cost-out initiatives, including:Repair vs. replace analyticsUse of refurbished/rebuilt componentsReduction in emergency purchases and premium freightMonitor and reduce:Inventory carrying costsExcess and obsolete (E&O) inventoryTrack and improve financial KPIs:Inventory turnsCost per operating hourMaintenance cost per pound producedAdvanced Data Analytics & Decision SupportOwn MRO data governance within CMMS/ERP:Item master accuracy (descriptions, specs, cross-references)BOM (Bill of Materials) integrity for all key assetsBuild and maintain analytics dashboards, such as:Stockout events vs. downtime impactParts usage trends by equipment and failure modeSpend by vendor, category, and asset classPerform predictive analysis:Anticipate part demand based on production schedules and historical failuresIdentify hidden inefficiencies:Overstocked but unused itemsFrequently expedited parts (poor planning signal)Provide actionable insights to:Maintenance leadershipPlant leadershipSupply chain teamsVendor Strategy & Supply Risk ManagementClassify suppliers based on criticality:OEMs for specialized automation componentsStrategic distributors for high-use consumablesLead supplier performance management:On-time deliveryLead-time consistencyPricing competitivenessNegotiate:Blanket POs for high-usage itemsConsignment/VMI programsEmergency supply agreementsDevelop multi-sourcing strategies for high-risk partsMitigate risk of:Single-source dependencyLong-lead imported componentsCoordinate rapid-response sourcing during uptime emergenciesWarehouse & Inventory Control ExcellenceEstablish best practices for MRO storeroom operations:Logical bin locations aligned to usage frequencyClear labeling and barcoding standardsLead and enforce cycle counting programs:Daily/weekly cadence based on criticality tiersInvestigate and resolve discrepancies:Root causes (process gaps, improper usage tracking, etc.)Drive 5S and visual management in storeroom areasImprove technician experience:Fast part identification and retrievalReduced time searching for materialsImplement controls for:Unauthorized withdrawalsUntracked parts usage (key data integrity risk)Cross-Functional LeadershipAct as the bridge between Maintenance, Operations, Finance, and Procurement.Participate in:Daily production/maintenance meetingsWeekly reliability reviewsBudget reviews and capital planning sessionsEducate internal stakeholders on:Inventory implications of maintenance decisionsCost vs. reliability trade-offsInfluence behavior:Reduce “just-in-case” hoarding or over-orderingPromote planned vs. reactive maintenance cultureRegulatory, Food Safety & Audit ReadinessEnsure all MRO processes comply with:USDA requirementsFood safety standards (GMPs, HACCP support)Manage proper storage of:Food-grade lubricantsChemicals and maintenance materialsMaintain audit-ready documentation:Inventory transactionsSupplier traceability where requiredSupport internal and external audits:Provide immediate visibility to inventory recordsDemonstrate control over maintenance materialsContinuous Improvement & DigitizationLead or support Lean / Six Sigma initiatives such as:Storeroom optimizationInventory reduction without increasing riskImplement:Barcode/RFID solutionsMobile technician part issuanceDrive CMMS maturity improvements:Increased technician adoptionImproved data capture qualityBenchmark against industry best practices for:MRO inventory turnsMaintenance cost as % of asset valueWhat “Strong Performance” Looks Like in This RoleNo production downtime due to part unavailabilitySignificant reduction in emergency purchase ordersImproved maintenance efficiency (more planned work, less reactive)Inventory reduced without increasing operational riskClear, data-backed decisions driving reliability and cost controlKey Performance Indicators (KPIs)Inventory accuracy ≥ 98%Stockout rate reductionEquipment downtime attributable to parts availabilityInventory turns improvementR&M budget adherenceObsolescence reduction