Fortune 500 Industrial Manufacturer saves $10.5M by harmonizing MRO inventory data across 29 plants

The manufacturer faced fragmented MRO inventory management across 29 plants, with non-standardized data practices and siloed decision-making. Limited cross-plant visibility made it difficult to balance overstock against stockout risk. Multiple ERP instances created disjointed inventory management, increasing working capital exposure.

The organization deployed Verusen's AI-driven MRO inventory optimization platform to consolidate all MRO data into a single source of truth across 29 plants. The platform identified over 3,000 potential duplicate materials, improved procurement insights for supplier rationalization, and enabled modernization of outdated stocking policies enterprise-wide—without requiring ERP migrations.

The initiative identified $20.9M in inventory savings opportunities and verified $10.5M in actual savings. Over 800 material stocking policies were updated, and approximately 2,000 materials at stockout risk were flagged. Verified reductions of $55K per hour were measured during the first six months.

• Centralizing MRO data across ERP systems is a prerequisite for enterprise-wide inventory governance; cross-plant visibility unlocks savings invisible at the plant level.
• AI-driven duplicate material identification (3,000+ flagged) is a high-ROI early step that doesn't require process overhaul.
• Modernizing stocking policies based on unified data can simultaneously reduce overstock and stockout risk without increasing overall inventory.