Dead / Obsolete Inventory

Definition

Control of unusable, obsolete and dead stock. This reference is designed for practical industrial stores, MRO, production and materials-management environments.

Objective

Control inventory with no foreseeable operational use or with obsolete specification/status.

Scope

Apply the method at item, category, location or plant level as appropriate. The control should connect planning, purchasing, stores transactions, physical verification and management review.

Required Inputs

Last movement
future requirement
specification status
replacement model
shelf life.

Methodology

Define the business requirement, scope and review period.
Validate item master, consumption, stock and open transaction data.
Calculate or classify using the defined method.
Compare the result with criticality, supplier constraints and future demand.
Assign an action owner, due date and review frequency.
Monitor KPI movement and revise parameters when conditions change.

Formula / Control Logic

Dead/obsolete status requires documented evidence of no expected use or obsolete condition.

Worked Industrial Example

A discontinued component replaced by a new approved model may become obsolete after remaining demand is closed.

Decision Rules

Use engineering and user confirmation.
Check alternate applications and inter-unit transfer.
Follow disposal/approval procedure.

Industrial Controls

Authorized master-data and parameter changes
ERP transaction discipline and document traceability
Physical verification and reconciliation
Exception reporting with named ownership
Periodic management review of ageing, service and capital exposure

KPIs

Service

Availability, fill rate and stock-out performance.

Accuracy

Book-to-physical reliability and transaction quality.

Capital

Turnover, coverage, ageing, excess and dead stock.

Common Errors

Writing off without user confirmation.
Ignoring repairability or alternate use.
Keeping obsolete stock indefinitely.

Excel / MIS Application

Useful fields: Item Code, Description, UOM, Opening Qty, Receipt Qty, Issue Qty, Closing Qty, Unit Rate, Annual Consumption, Current Stock, Open PO, Lead Time, Safety Stock, ROP, Min, Max, ROQ, ABC, VED, FSN, Ageing, Action.

Management Review Questions

Which items require action now, and why?
Are open orders aligned with actual requirement?
Which exceptions are recurring and what is the root cause?
Which parameter should be changed, and what evidence supports the change?

Related Inventory References

Professional practice: A calculation is a control aid, not a substitute for engineering judgement, approved policy, physical verification or business-risk assessment.