{"id":37833,"date":"2026-03-04T22:42:38","date_gmt":"2026-03-04T22:42:38","guid":{"rendered":"https:\/\/www.argonandco.com\/?post_type=article&p=37833"},"modified":"2026-03-04T22:42:38","modified_gmt":"2026-03-04T22:42:38","slug":"inventory-optimisation-in-asset-intensive-industries-maximising-working-capital-without-compromising-uptime","status":"publish","type":"article","link":"https:\/\/www.argonandco.com\/en\/news-insights\/articles\/inventory-optimisation-in-asset-intensive-industries-maximising-working-capital-without-compromising-uptime\/","title":{"rendered":"Inventory Optimisation in Asset-Intensive Industries: Maximising Working Capital Without Compromising Uptime"},"content":{"rendered":"

Asset-intensive organisations, including mining, oil & gas, utilities, heavy\u00a0manufacturing\u00a0and infrastructure, carry\u00a0significant inventory\u00a0in\u00a0spare parts,\u00a0consumables\u00a0and maintenance supplies. This inventory is\u00a0essential to keep assets\u00a0operating\u00a0reliably, but they also\u00a0represent\u00a0significant working capital tied up on the balance sheet.<\/span>\u00a0<\/span><\/p>\n

When inventory is mismanaged, whether through overstocking, poor data, or misalignment with maintenance needs, organisations can\u00a0lock up\u00a0large amounts\u00a0of working capital\u00a0whilst at the same time face\u00a0increased risk of\u00a0asset\u00a0downtime. The challenge is therefore not simply to hold less inventory, but to hold the right inventory, in the right place, at the right time –\u00a0freeing up capital while\u00a0maintaining\u00a0uptime and reliability.<\/span>\u00a0<\/span><\/p>\n

The Working Capital Dilemma<\/span><\/b>\u00a0<\/span><\/h3>\n

Inventory is one of the largest components of working capital for heavy industry.\u00a0Yet,\u00a0organisations often have excessive stock on hand while still experiencing critical stock-outs when key parts are needed most. This paradox highlights a deeper issue: inventory optimisation\u00a0isn\u2019t\u00a0just about reducing\u00a0totals.\u00a0It\u2019s\u00a0about alignment with operational demand and asset strategy.<\/span>\u00a0<\/span><\/p>\n

Excessive inventory ties up capital at significant cost. Industry data shows that carrying costs, encompassing warehousing, insurance, depreciation, and obsolescence risk, can amount to 20\u201330% of total inventory value annually, draining profits and locking up cash that could be deployed elsewhere.\u00a0<\/span>\u00a0<\/span><\/p>\n

Conversely, stock-outs disrupt maintenance schedules, reduce asset\u00a0availability\u00a0and often trigger\u00a0expensive emergency procurement and expedited freight, further eroding margins.<\/span><\/p>\n

Common Root Causes of Sub-Optimal Inventory<\/span><\/b>\u00a0<\/span><\/h3>\n

Asset-intensive organisations face several recurring challenges when it comes to inventory:<\/span>\u00a0<\/span><\/p>\n

    \n
  • Misaligned stock and maintenance planning\u00a0\u2014 Inventory strategies\u00a0aren\u2019t\u00a0linked to actual maintenance schedules or asset criticality, leading to both redundancy and gaps.\u00a0<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
      \n
    • Poor master data quality\u00a0\u2014 Inaccurate material descriptions, duplicated records, and inconsistent nomenclature undermine forecasting and planning systems.\u00a0<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
        \n
      • Siloed organisational structures\u00a0\u2014 Procurement, inventory and maintenance functions often\u00a0operate\u00a0independently, resulting in inconsistent prioritisation and accountability.\u00a0<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
          \n
        • Reactive replenishment and planning\u00a0\u2014 Lack of proactive demand forecasting means organisations chase stock after the fact, instead of\u00a0anticipating\u00a0needs based on maintenance plans and asset wear patterns.\u00a0<\/span>\u00a0<\/span><\/li>\n<\/ul>\n

          These gaps compound over time, locking capital in low-value inventory and increasing the likelihood of unplanned work and downtime.<\/span>\u00a0<\/span><\/p>\n

          Criticality-Based Inventory Management: Reducing Risk, Freeing Capital<\/span><\/b>\u00a0<\/span><\/h3>\n

          A powerful way to reduce inventory while\u00a0maintaining\u00a0uptime is to adopt\u00a0criticality-based inventory management. Rather than treating all SKUs alike, items are classified not just by value or usage, but by their\u00a0impact on operations\u00a0if they become unavailable.<\/span>\u00a0<\/span><\/p>\n

          How Classification Drives Optimisation<\/span><\/b>\u00a0<\/span><\/h3>\n
            \n
          • High-criticality\/low-volume parts\u00a0\u2014 Essential to uptime; stock levels tightly controlled and\u00a0monitored.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
              \n
            • High-volume\/low-criticality items\u00a0\u2014 Managed with efficient replenishment but without excessive safety stock.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                \n
              • Low-criticality\/low-volume inventory\u00a0\u2014 Candidates for reduction or alternate fulfilment models.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n

                Hybrid approaches (e.g., ABC-VED analysis) help organisations focus capital on parts that matter most to reliability, ensuring safety and uptime without tying up unnecessary stock.\u00a0<\/span>\u00a0<\/span><\/p>\n

                This approach supports\u00a0smarter safety stock settings, driven by actual maintenance schedules and lead-time variability, not arbitrary days-on-hand rules.<\/span>\u00a0<\/span><\/p>\n

                Integrating Inventory\u00a0with\u00a0Maintenance and Operations<\/span><\/b>\u00a0<\/span><\/h3>\n

                Inventory optimisation\u00a0shouldn\u2019t\u00a0be insulated from maintenance\u00a0strategy,\u00a0it must be\u00a0integrated with asset-level planning.<\/span>\u00a0<\/span><\/p>\n

                When planning, maintenance teams should partner with supply chain and procurement to:<\/span>\u00a0<\/span><\/p>\n

                  \n
                • Align\u00a0maintenance work orders and planned outages\u00a0with inventory levels.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                    \n
                  • Use predictive and preventive asset data to estimate true consumption.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                      \n
                    • Remap bills of material (BOMs) for assets so planned maintenance genuinely reflects inventory demand.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n

                      This integration reduces reliance on emergency orders and increases confidence that necessary parts will be on hand when needed. It also enables inventory systems (ERP, CMMS\/EAM) to\u00a0operate\u00a0with\u00a0consistent, high-quality data, improving planning outcomes.\u00a0<\/span><\/p>\n

                      Optimisation Beyond Reduction: Smarter Policies and Collaboration<\/span><\/b>\u00a0<\/span><\/h3>\n

                      Inventory optimisation\u00a0isn\u2019t\u00a0merely about cutting levels; it involves\u00a0better decision-making, governance, and cross-functional collaboration:<\/span>\u00a0<\/span><\/p>\n

                        \n
                      • Master Data Management\u00a0\u2014 Cleansing and standardising material records improves forecasting accuracy and reduces duplicate purchases.\u00a0<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                          \n
                        • Demand-Driven Replenishment\u00a0\u2014 Triggering orders based on actual usage patterns rather than fixed periodic cycles.<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                            \n
                          • Supplier Collaboration Models\u00a0\u2014 Vendor-managed inventory (VMI) and consignment stock can reduce internal carrying costs while improving service levels.\u00a0<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                              \n
                            • Shared KPIs Across Functions\u00a0\u2014 Aligning finance, operations, maintenance, and procurement around metrics such as service level, stock-out rates, and working-capital efficiency.\u00a0<\/span>\u00a0<\/span><\/li>\n<\/ul>\n

                              In capital-intensive environments, this shift from tactical, siloed behaviour to\u00a0strategic inventory governance\u00a0is a key enabler of both financial and operational performance.<\/span>\u00a0<\/span><\/p>\n

                              Delivering Sustainable Cash and Resilience<\/span><\/b>\u00a0<\/span><\/h3>\n

                              When executed well, inventory optimisation programs can deliver\u00a0measurable financial results:<\/span>\u00a0<\/span><\/p>\n

                                \n
                              • Talented teams have reduced inventory holdings by\u00a015\u201330%\u00a0while\u00a0maintaining\u00a0or improving service levels.\u00a0<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                                  \n
                                • Reductions of tens of millions in inventory value can materially improve free cash flow, strengthen balance sheets, and unlock funds for strategic growth or debt reduction.\u00a0<\/span>\u00a0<\/span><\/li>\n<\/ul>\n

                                  Importantly, this helps organisations manage cash more effectively in volatile markets,\u00a0balancing liquidity pressures with uptime commitments.<\/span>\u00a0<\/span><\/p>\n

                                  Conclusion<\/span><\/b>\u00a0<\/span><\/h3>\n
                                    \n
                                  • Optimising inventory in heavy and asset-intensive industries is not about simple stock cuts.\u00a0It\u2019s\u00a0about\u00a0taking capital out of unnecessary inventory without risking uptime, through:<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                                      \n
                                    • Better classification and criticality-based strategies<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                                        \n
                                      • Stronger alignment between inventory,\u00a0maintenance\u00a0and operations<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                                          \n
                                        • Improved data quality and cross-functional governance<\/span>\u00a0<\/span><\/li>\n<\/ul>\n
                                            \n
                                          • Smarter replenishment and supplier collaboration<\/span>\u00a0<\/span><\/li>\n<\/ul>\n

                                            Done correctly, inventory optimisation becomes a powerful tool to\u00a0unlock working capital, protect operational reliability, and strengthen organisational resilience\u00a0in competitive and volatile market environments.<\/span>\u00a0<\/span><\/p>\n

                                            How Argon & Co helps\u00a0<\/span>\u00a0<\/span><\/h3>\n

                                            Argon & Co routinely delivers large procurement improvement and cost reduction programs to support heavy industry companies to protect their\u00a0and strengthen their margins\u00a0\u2013 we help clients find the money, get the money, and keep the money.\u00a0<\/span>\u00a0<\/span><\/p>\n

                                            Our approach combines deep operational understanding with commercial\u00a0discipline, ensuring cost reduction does not come at the expense of reliability, safety, or performance.\u00a0<\/span>\u00a0<\/span><\/p>\n

                                            Contact us today to discuss how a targeted procurement health check could unlock immediate savings and build lasting margin resilience.<\/span>\u00a0<\/span><\/p>\n","protected":false},"featured_media":37842,"template":"","categories":[],"region":[160,162,273],"class_list":["post-37833","article","type-article","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"\nInventory Optimisation in Asset-Intensive Industries: Maximising Working Capital Without Compromising Uptime - Argon & Co<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.argonandco.com\/en\/news-insights\/articles\/inventory-optimisation-in-asset-intensive-industries-maximising-working-capital-without-compromising-uptime\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Inventory Optimisation in Asset-Intensive Industries: Maximising Working Capital Without Compromising Uptime - Argon & Co\" \/>\n<meta property=\"og:description\" content=\"Asset-intensive organisations, including mining, oil & gas, utilities, heavy\u00a0manufacturing\u00a0and infrastructure, carry\u00a0significant inventory\u00a0in\u00a0spare parts,\u00a0consumables\u00a0and maintenance supplies. 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