Assigning Spare Parts Management Decision-Making Strategies: A Holistic Portfolio Classification Methodology

Maintenance organizations face growing volumes of spare parts, requiring robust classification methodologies to support decision-making. Practitioners continue to rely on simple and single-criterion-specialized methodologies, while research advances toward criteria- and threshold-specialized classification optimization for operationally visible spare parts or predefined classes, revealing criteria dependencies and data completeness requirements. The literature review identifies a gap showing that existing classification methodologies lack inclusion of all spare parts with maintainable asset relevance, consequently excluding, under-prioritizing, or misclassifying essential spare parts, leading to the wrong forecasts and inventory policies. Applying design science research, this study develops a holistic spare parts portfolio classification methodology that increases spare parts inclusion and enables class-based decision-making strategy development to address the gap. The methodology classifies spare parts based on their absence and presence across equipment bills of materials, maintenance history, inventory, and inventory policies, enabling identification and inclusion of operationally invisible spare parts. A case study of 32,521 spare parts demonstrates the interventional effects of the methodology. The intervention improved decision-making efficiency by 91%, increased decision throughput ninefold, and transformed a non-transparent decision-making approach with 9% scope completion and 1.7% stock value increase into a transparent strategy-based approach yielding full scope completion and 33.6% scope stock value reduction.