MR-04 · Component & Parts Management · Airlines Process Wiki

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Process Flow Diagram (BPMN)

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L4 Process Steps

Step	Step Name	Role / Swim Lane	System	Input	Output	KPI	Dec?	Exc?
Phase 1 1.1	Generate parts demand forecast from maintenance programme	Materials Planning Analyst	AMOS by Swiss AviationSoftware	Approved maintenance programme, fleet utilisation plan, AD/SB list	12-month rolling parts demand forecast by P/N	Forecast accuracy ≥85% (MAPE ≤15%)	N	N
1.2	Validate forecast against consumption history and ADs	Materials Planning Analyst	AMOS by Swiss AviationSoftware	24-month parts consumption history, current AD/SB revision delta	Validated demand plan with confidence bands; exception list for manual override	Forecast review cycle completed within 5 business days	Y	N
1.3	Submit demand plan to procurement and finance for budget approval	Materials Planning Manager	SAP S/4HANA Finance (FI/CO)	Validated demand plan, prior-year actuals	Approved materials budget, MRP requirements released to procurement	Budget approval lead time ≤10 business days	N	N
Phase 2 2.1	Check stock availability against net demand requirements	Materials Controller	AMOS by Swiss AviationSoftware	Approved demand plan, real-time inventory snapshot	Net requirements list with buy / borrow / exchange decisions per P/N	Stock-out rate ≤2% for critical AOG-flagged parts	Y	N
2.2	Source parts from approved vendor list via RFQ	Procurement Specialist	SAP Ariba	Net requirements list, approved vendor master, contract pricing	RFQ issued to ≥2 approved suppliers per part number	Vendor lead time compliance ≥90%; RFQ issued within 1 business day of requirement	N	Y
2.3	Evaluate supplier quotes and select preferred source	Procurement Specialist	SAP Ariba	Supplier quotes, cost and lead-time matrix, AOG flag	Awarded PO, supplier selection rationale documented	PO cycle time ≤3 business days (AOG: ≤4 hours)	Y	Y
2.4	Issue purchase order and confirm supplier delivery commitment	Procurement Manager	SAP S/4HANA Finance (FI/CO)	Awarded quote, budget confirmation, delivery address	PO issued with confirmed expected receipt date and freight tracking reference	PO-to-delivery on-time rate ≥88%	N	N
Phase 3 3.1	Receive parts shipment and verify airworthiness documentation	Stores Receiving Inspector	AMOS by Swiss AviationSoftware	Inbound shipment, packing list, FAA 8130-3 or EASA Form 1	Goods receipt logged in AMOS; documents scanned and attached to part record	Receiving processing time ≤4 hours for AOG-flagged parts; ≤24 hours for routine receipts	N	Y
3.2	Inspect parts for airworthiness and serviceable condition	Quality Inspector (Part 145 authorised)	AMOS by Swiss AviationSoftware	Physical part, airworthiness release certificate, inspection checklist	Inspection record; pass/fail determination recorded against part in AMOS	Inspection turn-time ≤8 hours; incoming rejection rate ≤3%	Y	Y
3.3	Quarantine non-conforming parts and raise supplier NCR	Quality Inspector	AMOS by Swiss AviationSoftware	Failed inspection record, non-conformance details	Quarantine tag applied, Non-Conformance Report raised, supplier notified	NCR resolution cycle ≤15 business days; quarantined parts segregated within 1 hour of rejection	N	Y
Phase 4 4.1	Assign bin location and update AMOS inventory record	Stores Clerk	AMOS by Swiss AviationSoftware	Accepted and inspected part, warehouse bin map	Part binned, inventory record updated with location, quantity, and batch traceability	Inventory location accuracy ≥99.5%; bin assignment completed within 2 hours of acceptance	N	N
4.2	Monitor shelf-life, expiry dates, and life-limited part counters	Materials Controller	AMOS by Swiss AviationSoftware	Part life data, calendar expiry dates, flight-cycle counters from OEM CMM	Expiry alerts actioned; scrapping orders raised for time-expired or cycle-expired parts	Shelf-life compliance 100%; zero expired parts issued from serviceable stock	Y	Y
4.3	Conduct periodic cycle counts and reconcile inventory discrepancies	Stores Supervisor	AMOS by Swiss AviationSoftware	Cycle count schedule, physical count results, AMOS on-hand quantities	Reconciled inventory record; adjustment or write-off requests submitted to Finance	Inventory accuracy post-count ≥99%; cycle count variance ≤1% by value	N	N
Phase 5 5.1	Receive and validate parts request from maintenance work order	Materials Controller	AMOS by Swiss AviationSoftware	Work order task card, illustrated parts catalogue reference, parts list	Validated picking list generated in AMOS; estimated staging time confirmed to technician	Parts picking initiated within 30 minutes of WO request submission	N	N
5.2	Kit and stage parts at work centre before task start	Stores Clerk	AMOS by Swiss AviationSoftware	Validated picking list, bin locations, task start time	Kitted parts trolley staged at work centre; all P/Ns and quantities verified	Kitting accuracy ≥99%; kit staged ≥1 hour before scheduled task start	Y	Y
5.3	Issue parts to technician and record WO consumption in AMOS	Stores Clerk	AMOS by Swiss AviationSoftware	Kitted parts, technician badge and signature, work order number	Parts issued; WO consumption record updated; removed serviceable/unserviceable parts tagged and returned to stores	Parts issuance documentation completeness 100%; removed parts tagged within 1 hour of removal	N	N
Phase 6 6.1	Tag and track removed unserviceable rotable in AMOS	Maintenance Technician	AMOS by Swiss AviationSoftware	Removed component, completed work order removal record	Unserviceable tag applied; unit status set to U/S in AMOS rotable tracking module with part history appended	Rotable U/S tagging compliance 100%; AMOS update completed within 4 hours of removal	N	N
6.2	Assess repair viability against BER threshold	Component Engineering Manager	AMOS by Swiss AviationSoftware	Unserviceable rotable, OEM Component Maintenance Manual, preliminary repair cost estimate	Repair or BER decision documented; repair order raised in AMOS or scrapping order approved	BER rate ≤8% of annual rotable pool; average repair cost vs. new-unit cost ≤60%	Y	Y
6.3	Ship core to approved repair agency and track shop visit TAT	Rotables Controller	AMOS by Swiss AviationSoftware	Raised repair order, serviceable-to-repair shipping documentation, export/import permits	Core shipped with AMOS shop visit opened; TAT clock started; interim exchange unit sourced if required	Repair TAT ≤30 days for avionics LRUs; ≤60 days for engine accessory components	N	N
6.4	Receive repaired rotable and return to serviceable stock	Stores Receiving Inspector	AMOS by Swiss AviationSoftware	Repaired unit, MRO shop work order, EASA Form 1 or FAA 8130-3, updated part history	Rotable returned to serviceable stock in AMOS; shop visit closed; cost posted to SAP asset record	Rotable pool availability rate ≥92%; receiving and return-to-stock processing ≤4 hours	Y	Y

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Process Attributes

Identification

Process IDMR-04

L1 DomainMaintenance, Repair & Overhaul

L2 ProcessEngine & Component Shop

L3 NameComponent & Parts Management

L4 Steps20 across 6 phases

Decision Gates8 (all with iteration loops)

Exceptions9 documented

Swim Lanes (Roles)

Materials Planning Analyst

Materials Planning Manager

Materials Controller

Procurement Specialist

Procurement Manager

Stores Receiving Inspector

Quality Inspector (Part 145 authorised)

Quality Inspector

Stores Clerk

Stores Supervisor

Maintenance Technician

Component Engineering Manager

Rotables Controller

Systems & Tools

AMOS by Swiss AviationSoftwareSAP S/4HANA Finance (FI/CO)SAP Ariba

Key Performance Indicators

Generate parts demand forecast from maintenance programmeForecast accuracy ≥85% (MAPE ≤15%)

Validate forecast against consumption history and ADsForecast review cycle completed within 5 business days

Submit demand plan to procurement and finance for budget approvalBudget approval lead time ≤10 business days

Check stock availability against net demand requirementsStock-out rate ≤2% for critical AOG-flagged parts

Source parts from approved vendor list via RFQVendor lead time compliance ≥90%; RFQ issued within 1 business day of requirement

Evaluate supplier quotes and select preferred sourcePO cycle time ≤3 business days (AOG: ≤4 hours)

Issue purchase order and confirm supplier delivery commitmentPO-to-delivery on-time rate ≥88%

Receive parts shipment and verify airworthiness documentationReceiving processing time ≤4 hours for AOG-flagged parts; ≤24 hours for routine receipts

Airline-Specific Risks & Pain Points

Fleet mix changes (737 MAX vs 737-800 intermix) cause demand volatility; AMOS forecast module requires manual adjustment for new-type introductions where consumption history is sparse

Sporadic demand items (rotables with <4 removals/year) produce unreliable AMOS statistical forecasts; manual override requires SME judgement and is not auditable within AMOS

No native AMOS–SAP interface at many carriers; demand plan must be manually re-keyed into SAP MRP, introducing transcription errors and plan drift between systems

Inventory accuracy degrades when technicians issue parts without closing work orders in AMOS; phantom stock causes missed AOG events and emergency buys that erode savings from planned procurement

FAA/EASA Part 145 approved supplier list is slow to update; unapproved parts risk is highest on spot-market buys where non-qualified vendors are used to satisfy urgent demand

AOG situations force bypass of normal sourcing controls; expedited buys from non-preferred vendors increase counterfeit-part risk and undermine FAR Part 145 traceability requirements

Inputs / Outputs

Primary InputApproved maintenance programme, fleet utilisation plan, AD/SB list

Primary OutputRotable returned to serviceable stock in AMOS; shop visit closed; cost posted to SAP asset record

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