Inventory, Breakdown, and Lessons in Plant Maintenance: Reflections - 2nd March, 2025
More inventory does not always mean better availability of spares. In fact, the more unnecessary inventory you have, the less likely you are to find the exact spare you need when a breakdown happens. This thought crossed my mind when I heard about the breakdown of a bucket elevator gearbox at Sebit, West Pokot plant —a place where I worked for a short time. The plant was shut down for 12 days due to the unavailability of a spare gearbox. Unfortunately, this is a recurring issue there. There was no scientific approach to procurement—just blind purchasing to save their skins. But in reality, no one can escape the consequences of poor planning. And then there’s the bigger issue: it was an old Chinese plant. After running its full life in China and being exploited to the maximum, it was sold to Devki Group, Kenya. Imagine the situation for a mechanical maintenance engineer in a plant like this—no proper manuals, no part lists, and no structured systems. Every day and every night...