Tool

Spares Criticality & Replenishment Matrix

Interactive tool to classify spares by criticality, capture demand, lead time, cost, RCM and PM links, and record replenishment rules and suggested min/max/ROP using practical formulas. Saves structured records for later review or export.

Interactive Tool

Spares Criticality & Replenishment Matrix — Recorder

This form helps you classify one spare part, capture the parameters you need for replenishment decisions, and record a suggested replenishment rule. Follow the guidance here to compute reorder points and min/max. Average daily demand = avg demand per month / 30. Reorder point (ROP) = (avg daily demand * lead time days) + safety stock. Safety stock can be estimated as (avg daily demand * safety stock days) or calculated from demand variability when data is available.

Fill the fields below, save the record, and repeat for other parts. Saved records can be exported or used to drive replenishment rules later.

Unique identifier used in your ERP or CMMS.
Short descriptive name.
Typical consumption rate. Use historical usage or estimated failure/consumption rate.
Time from order placement to receipt. Include typical freight & internal processing.
Reference to PM task IDs, asset tags, or checklist where this spare is used.
Typical target fill/service level. 95 is common for critical spares.
Rule-of-thumb days held as safety stock. Use empirical calculations where possible.
Compute using: (avg demand per day * lead time days) + safety stock. Avg demand per day = avg demand per month / 30.
Typical upper bound. Simple heuristic: suggested min + avg monthly demand (adjust for storage & obsolescence).
Set Q for reorder-point policies or the Kanban batch size. For EOQ use external calculator.
Include alternate part numbers, substitutes, vendor lead-time notes, or storage considerations.
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