Evaluation of Spare Parts Management and Supply Chain Practices in a Cement Factory in Benue State

Unplanned equipment downtime attributable to non-availability of spare parts is a major operational challenge in capital-intensive process industries across Nigeria, and the management of maintenance spare parts inventory involves complex trade-offs between holding costs and stockout risks. This study evaluates spare parts management and supply chain practices at a cement manufacturing facility in Gboko, Benue State. The assessment framework combined analysis of spare parts inventory records, interviews with procurement, stores, and maintenance management personnel, and mapping of the end-to-end parts sourcing and delivery process. Inventory performance metrics including service level, average holding value, stock turnover, and inactive inventory proportion were calculated. Supply chain lead times for both domestic and imported components were benchmarked against downtime duration data for corresponding equipment failures. Findings revealed an overall spare parts service level of 71 percent, meaning that 29 percent of parts requests experienced stockout delays that contributed to extended equipment downtime. Inactive inventory items accounted for 22 percent of total spare parts holding value, representing capital tied up in non-moving stock. Mean lead time for imported critical spares averaged 38 days, during which unplanned downtime for affected equipment could not be managed through stock availability. The study recommends application of criticality-based inventory classification, establishment of local vendor partnerships for fast-moving consumables, and creation of an emergency import procurement mechanism. Keywords: spare parts management, inventory control, cement factory, supply chain, Benue State.