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LYIT
LAST YARD INVENTORY TRACKING
Case Study

460 Hydraulic Room: 12-Month Stock Behaviour Review

What 12 months of shelf tracking shows about parts approaching zero
Reporting Period: 10 February 2025 — 28 February 2026 (12 months)

The Short Version

Over the past 12 months, LYIT tracked daily stock levels for 194 parts stored in the 460 Workshop Hydraulic Room.

During that time, many of those parts repeatedly trended toward zero stock. In this report these events are referred to as Zero Points.

Each Zero Point represents a point where the shelf was approaching empty and required replenishment to avoid running out.

If those shelves had reached zero, parts would likely have needed to be sourced reactively. In a remote operation this often means additional travel across site to retrieve parts from other locations.

This report reviews how often these situations occurred, what that represents in operational terms, and which parts are most frequently moving toward zero.

The goal is simple: to understand where shelf-level stock behaviour is creating risk and where small adjustments to minimum stock levels could stabilise supply.

434
Zero Points
Parts that trended toward zero stock
258
Potential Delay Hours
If a portion occurred during breakdown work
346
Additional HV Road Travel
Estimated retrieval travel exposure
33
Parts at Zero 7+ Days
Extended stockouts recorded

Not every Zero Point results in a delay, but if even a portion had resulted in breakdown events, the figures above show the potential operational impact.

What This Report Covers
This report reviews three areas:
1

Zero Point Frequency

How often parts in the Hydraulic Room trended toward zero stock over the 12 month period.

2

Operational Exposure

What those Zero Points represent in practical terms, including the potential travel required to source parts if shelves had reached zero.

3

Stock Stability

Which parts repeatedly struggled to remain stocked and where warehouse minimum levels may need adjustment.

What Running Out Can Cost

The figures below show what those Zero Points could represent if parts had reached zero and caused delays.

The numbers are based on simple planning assumptions. You can adjust the sliders to reflect how your site typically experiences delays.

When shelves repeatedly move toward zero, the risk isn't the stock level itself. The risk is the reactive work that follows when parts are no longer there.

$

Delay & Downtime Cost Model

434
20%
3.0 hrs
$15,000
Breakdown Events
81
Total Delay Exposure
243 hrs
Modelled Cost Exposure
$3.87M
These figures are planning indicators, not confirmed losses. They show the scale of risk when stock repeatedly runs near zero. Adjust the sliders to test different assumptions.
When Parts Move Toward Zero

This section examines Zero Points recorded at the WKSP-460 terminal over the 12-month reporting period.

A Zero Point occurs when stock drops to a level where, based on recent usage, the part would have reached zero if it had not been restocked. In simple terms, the shelf was heading toward empty.

This does not mean the part ran out or that downtime occurred. It shows the points where stock levels were approaching zero and required replenishment to avoid running out.

Tracking these points makes it possible to see how often shelves are moving toward empty and where that pattern repeats.

The chart below shows stock level tracking for the five parts with the highest Zero Point counts during the reporting period. It illustrates the typical cycle of parts being used, trending toward zero, and then being replenished.

Top 5 Parts by Zero Points - Stock Level Tracking - 460 Workshop - Hydraulic Room
What This Shows — A small group of parts repeatedly trended toward zero stock. These parts cycle quickly between use and replenishment, increasing the chance of shelves reaching zero if restocking is delayed.

How Often This Happened

Over the reporting period, 434 Zero Points were recorded across the monitored parts.

Using the same planning assumptions applied in the cost model:

  • If 20% of these situations had occurred during breakdown work,
  • And each event resulted in an average 3 hour delay while sourcing parts

This would represent:

  • 86 breakdown-related events
  • 258 hours of modelled delay exposure
Note: Small stock increases (≤5 units) are treated as stocktake adjustments and excluded from the Zero Point count. The 80:20 PM/BM split is a modelling assumption used for analysis and does not represent actual job classifications.
Additional HV Road Travel

When parts approach zero stock there is a higher chance they will need to be retrieved from surface stores. In remote operations this can mean additional heavy-vehicle travel across site.

To estimate this impact, the 434 Zero Points were split using a simple planning assumption.

It is assumed that:

173 retrieval trips × 2 hours = 346 hours

of additional heavy-vehicle road travel

Use the sliders below to test different site conditions. You can adjust the percentage of events requiring a dedicated trip and the typical travel time per retrieval.

!

Road Safety Exposure Model

40%
2.0 hrs
Separate Retrieval Trips
173
HV Road Exposure
346 hrs
Note: The 2-hour travel estimate represents road time only. The 3-hour delay used in the breakdown modelling includes travel plus the time required to locate, issue, and return the part to the job.

Why This Matters on Site

The roads between the terminal and surface stores carry regular heavy-vehicle traffic. HV/LV interaction is a recognised risk area on site.

Additional retrieval trips increase the time personnel spend on these roads and increase overall exposure.

These figures represent estimated exposure based on the planning assumptions used in this report.

Parts That Reached Zero

This section highlights the 33 parts that remained at zero stock for 7 or more consecutive days.

During these periods the workshop did not have the part available on the shelf.

Extended zero-stock periods usually indicate a mismatch between how quickly a part is used and how quickly it is replenished.

The table below shows usage patterns for these parts, including total consumption, restock frequency, and an indicative minimum stock level for the central warehouse.

Indicative minimum levels are based on average usage scaled to a four-month lead time. These figures reflect usage at this terminal only. Site-wide consumption should also be considered when setting final reorder levels.

Part Number Days at Zero Occurrences Total Usage Restocks Indicative Min Stock Severity
Note: Only zero-stock periods of 7 or more consecutive days are included.
Table Key
Days at Zero — Total number of days the part remained at zero stock.
Occurrences — Number of separate zero-stock events recorded.
Total Usage — Total quantity consumed during the reporting period.
Restocks — Number of restocking events detected.
Indicative Minimum Stock — Suggested central warehouse minimum based on usage and a four-month lead time, including a 1.5× safety factor. Terminal usage only.

Operational Takeaways

This report analysed 12 months of shelf-level stock behaviour for 194 parts stored in the 460 Hydraulic Room.

During that period:

Together these patterns show how stock is behaving at the point of use. Most parts cycle through normal depletion and replenishment.

However, repeated Zero Points and extended zero-stock periods indicate where current minimum levels may not reflect actual usage.

The purpose of this analysis is not to eliminate all low-stock situations. It is to make shelf behaviour visible so adjustments can be made before stockouts begin affecting work.

Small changes to warehouse minimum levels for high-use parts can often stabilise supply and reduce the need for reactive retrieval trips.

One year of data provides a clear picture of where those adjustments may have the greatest impact.

Areas to Review

The patterns observed in this report suggest several areas that may be worth reviewing.

Warehouse Minimum Levels

Parts that repeatedly trended toward zero stock may benefit from slightly higher minimum stock levels at the central warehouse.

Restocking Frequency

High-use parts with frequent Zero Points may require more frequent replenishment cycles.

Extended Zero-Stock Parts

Parts that remained at zero for extended periods may indicate a mismatch between consumption and current reorder levels.

Travel Exposure

Where parts are regularly retrieved from surface stores, adjusting local stock levels may reduce the need for additional retrieval trips.

These observations are based on usage patterns recorded at the WKSP-460 terminal over the reporting period. Site-wide consumption and operational context should also be considered when setting final stock levels.

LYIT catches the gaps before they cost you

Daily stock visibility. Low-stock alerts. Data-driven reorder recommendations. One hydraulic room, 434 near-misses caught, millions in potential exposure identified.