Spare Parts Stock Reconciliation

CHALLENGE

The aerospace company was responsible for maintaining operational Chinook helicopters, where even minor inventory inaccuracies could delay critical repairs. A high level of unavailable or misplaced parts posed a direct risk to service readiness.

The business required third-party validation of:

• The number of parts in stock.
• The value of stock.
• The condition of each part.
• The location of items across sites.

Due to the complexity and critical nature of the stock, the customer needed a fast, reliable solution that delivered results in real time, without compromising operational accuracy.

WHY RGIS?

The aerospace company selected RGIS for its ability to deliver a bespoke inventory audit programme, tailored to high-value and mission-critical industrial components. RGIS’s proven experience in industrial and aerospace stocktakes, combined with real-time reporting tools and the capability to scale teams rapidly across locations, made us the ideal partner.

OUR SOLUTION

RGIS designed a comprehensive project plan to meet the unique requirements of the customer:

• Custom-Built Inventory Programme: A bespoke solution was developed to handle the variety and sensitivity of the helicopter parts being audited.
• Real-Time Variance Reporting: RGIS generated live variance reports, giving immediate visibility of discrepancies.
• Simultaneous Location Counts: All inventory locations were audited at the same time to ensure global consistency and up-to-date reporting.
• Tight Operational Scheduling: A rigid, time-sensitive schedule ensured all sites were completed within the required window.
• Detailed Data Capture: In addition to quantity and location, RGIS recorded stock value and item condition, offering deeper operational insight.

RESULTS

• Immediate Visibility of Gaps: A significant number of parts were discovered to be not located where expected, highlighting systemic inventory management issues.
• Unified Global Data Set: Because all locations were counted simultaneously, the business had a single point-in-time view of its entire helicopter parts inventory.
• Faster Response Capability: The customer is now able to quickly identify and prioritise parts needed for immediate repair work, improving readiness and efficiency.
• Condition Awareness: By understanding the physical state of parts, the company can better forecast replacements and reduce the risk of using faulty components.

CONCLUSION

This project reinforced the value of using a trusted third party like RGIS for high-stakes inventory audits. The aerospace company now has enhanced visibility of its operational stock, reduced the risk of delays in helicopter servicing, and can make better-informed decisions based on real-time inventory data.