Stockout
A stockout occurs when a required spare part or maintenance material is unavailable when it is needed.
What this term means in maintenance
A stockout occurs when a required spare part or maintenance material is unavailable when it is needed.
Why maintenance stockouts matter
A stockout can extend downtime even when the failure has been diagnosed and labor is available.
Consequences may include:
- Production loss
- Expedited freight
- Temporary or unsafe substitutions
- Cannibalizing another asset
- Longer contractor waiting time
- Schedule disruption
- Increased repair cost
Practical example
A gearbox bearing fails during production. The inventory system shows one bearing available, but the store location is empty because a previous issue was not recorded. The plant loses additional time sourcing the part.
Common causes
Stockouts may result from:
- Incorrect stock balance
- Poor reorder settings
- Unrecorded issues
- Supplier delay
- Duplicate part records
- Unexpected demand
- Incorrect asset BOM
- Obsolete or superseded parts
Preventing stockouts
Controls include cycle counting, critical-spares review, accurate transactions, supplier monitoring, and review of parts that repeatedly delay work orders.
Common mistake
Increasing all stock levels after one shortage can create excess inventory without correcting the real data or process problem.
How this term differs
Stockout is the condition where a required item is not available. It is related to Stockout Rate, Spare Parts Service Level, and Inventory Fill Rate, but these terms describe different records, measures, roles, strategies, or decisions and should not be used interchangeably.
Related concepts
Related maintenance terms
Keep exploring connected CMMS, reliability, and maintenance planning terms.
Spare Parts Inventory
Spare parts inventory is the controlled stock of replacement components and consumables kept available to support equipment maintenance and reduce avoidable downtime.
Reorder Point
A reorder point is the inventory level at which replenishment should be initiated so expected demand can be covered during supplier lead time.
Inventory Cycle Counting
Inventory cycle counting is the regular verification of selected stock items so inventory accuracy can be maintained without waiting for a full annual count.
Glossary FAQs
- What causes maintenance stockouts?
Common causes include inaccurate balances, poor reorder settings, supplier delay, unrecorded issues, unexpected demand, and duplicate part records.
- How does a stockout affect maintenance?
It can extend downtime, disrupt schedules, increase expedited cost, and encourage unsuitable substitutions.
- How can stockouts be reduced?
Improve item data, cycle counts, reorder settings, critical-spares review, supplier monitoring, and issue discipline.