Your MRO Inventory Is Either Costing You Too Much
or Letting You Down
Find out which and fix it. Live in 7 days. USD $67K all in.
Most asset management teams can identify the symptoms without needing a consultant to name them: parts accumulating in stockrooms that have not moved in years, critical spares that stock out at the worst possible moment, and reorder levels that were set by someone who left the business three years ago and have not been reviewed since.
The question isn't whether MRO inventory optimisation is worth doing - it's whether the cost and effort to get started is justified.
That's exactly what COSOL MIO Essentials is designed to answer. For $67K all in, COSOL deploys IBM Maximo Inventory Optimization fully configured for your organisation - including user setup, monthly data load and validation, pre-built extraction scripts for SAP, Maximo and Ellipse, and eight hours of hands-on training. Live in 7 days. No large-scale implementation. No dedicated IT project.
For organisations managing up to $50M in MRO inventory, the cost reductions realised through COSOL Essentials typically build the business case for the full MIO Standard deployment - on their own.
Imagine the Possibilities
Before we go into the detail of this solution, take a look at these numbers below. These are not projections. They are the average IBM MIO customers outcomes across asset-centric sectors around the world (Statistics Source: IBM 2026).
Average Customer Outcomes
Download the factsheet on COSOL's MIO Essentials
The Costof Getting MRO Wrong
MRO inventory is one of the most overlooked sources of financial risk in asset-centric operations. The scale of the problem is consistent across industries.
MRO inventory is one of the most consistently underestimated sources of financial and operational risk in asset-intensive industries, and the data makes the scale of that risk difficult to ignore.
The Problem You're Already Paying For
Lost annually to unplanned downtime
Fortune Global 500 companies lose 11% of yearly turnover to equipment failures driven by poor parts availability.
Source: Siemens True Cost of Downtime, 2024 - cited by IBM Think Insights
Spent on MRO globally in 2024
Yet up to 60% of that inventory is excess, obsolete, or slow-moving at any given time.
Source: Industry analysts; excess/obsolete rate per Latentview / IBM MRO research
MRO parts bought today will sit unused for 5+ years
While holding costs consume another 20–30% of total inventory value, year after year.
Source: Industry MRO benchmarks
Three Reasons WhyMRO Optimization
Is Hard To Get Right
The Variable Load Is Unmanageable at Scale
The Right Answer Requires Cross-Functional Agreement
Your Recommendations Are Only As Good As Your Data
About COSOL's MIO Essentials
AI-Driven Inventory Optimization, Designed For Fast Deployment
COSOL MIO Essentials Benefits
- Analyzes each stock item across price, usage, movement, lead time, and criticality
- Recommends optimized reorder levels based on actual data, not assumption
- Identifies excess, obsolete, and slow-moving inventory across your stockroom
- Surfaces demand forecasting across 14 forecasting methods to match your environment
- Supports up to USD $50 million worth of inventory, with a clear upgrade path to the full platform as your needs grow.
COSOL MIO Essentials Inclusions and Deployment
USD $67,000 - all in.
Inclusions:
- IBM MIO Licence
Plus
- Pre-built data scripts for SAP, Maximo, and Ellipse - reducing setup time from weeks to days
- Configuration, user onboarding, and data validation included
- Hands-on training across two sessions to build internal capability from day one
- Optional advisory hours available as your team scales confidence and capability
- A direct path to the full MIO Standard platform when you are ready
The biggest differentiator for COSOL is our people. The organizations we work with cannot afford failure, so we only employ professionals who have deep expertise in asset management and the sectors we specialise in: utilities, infrastructure, natural resources, transport, and government. Reliable outcomes start with reliable people.
Outcomes You Can Expect
Achieve The Outcomes You Desire
Assets
- Increase asset productivity and economic output
- Increase service reliability and economic output
- Reduce cost of planned and unplanned downtime
- Extend economic life of assets and equipment
Costs
- Reduce external maintenance vendor spend
- Increase MRO inventory productivity
- Reduce cost of asset decommissioning and disposal
- Reduce ALM platform total cost of ownership (TCO)
Risk
- Reduce compliance process and regulatory cost
- Reduce service-level agreement (SLA) penalties
- Optimize risk-based asset investment spend
Workforce
- Increase operations and reliability engineering productivity
- Increase maintenance supervisor and staff productivity
- Reduce cost of inspections and quality
How It Integrates
MIO Essentials connects directly with your existing ERP and EAM systems. Pre-built scripts for SAP, Ellipse and Maximo mean faster data load and less configuration time. You are not starting from scratch.
Who It Is For
MIO Essentials is designed for inventory controllers, maintenance planners, and asset management leaders in asset-centric industries - including mining, utilities, transport, government, and infrastructure - who need fast, defensible results from their MRO investment.
Proof In The Field
IBM MRO IO Customer Successes (Source: IBM 2026)
Major Mining Company
- Operating 7 mine sites, and 1 terminal
- MRO Inventory Value decreased from $73M to $21M over 6-year period
- Achieved 50% year over year reduction in inventory for 6 years
- Improved asset uptime
Large Electric Utility
- Reduced inventory growth from 10% to 0%
- Improved asset uptime
- Net $77.8M spend allowance over 5 years
- Critical spares service level for generation improved to 99.7%
One of World's Largest Oil & Gas Companies
- Maintenance driven initiative to reduce inventory
- Lowered inventory levels by at least 10% for three years in a row
- Achieved over $90M in savings through rebalancing over three years
- Savings at single site funded global implementation in year 1
One of the World's largest Aluminum Manufacturers
- Maintenance driven initiative to reduce inventory
- $23M net inventory reductionin first 12 months
- $30M inventory reduction
- $7M inventory increase to minimize downtime
- Improved both asset uptime and service levels in the first 12 months
Why COSOL
Global Capability. Without the Global Cost or Complexity.
COSOL gives ambitious asset-centric organisations access to global enterprise asset management capability and technology, without the global enterprise cost, complexity, or risk. Delivered by experts with deep industry and technical experience to complement your team and accelerate your asset management maturity.
We are an IBM-certified delivery partner. We bring the technical depth to deploy MIO Essentials fast and the asset management experience to make sure it delivers in your environment - not just on paper.
Partnering with COSOL is not a handover engagement. True to our promise: When Reliability Matters, we stay accountable for outcomes, and with more than 25 years of experience serving asset management customers, we have the track record to back that up.
Specialists, not Generalists
Meet some of our Global Maximo Experts:
FAQs
Explore other Expert Insights
Download the factsheet on COSOL's MIO Essentials