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Rotables Process

Built for Pronto Xi ERP software, PSA Rotables Process enhances the visibility and tracking of your rotatable inventory items —from warehouse to changeout, repair and back to the warehouse

Take Control of Rotable Items in Your Changeouts

At PSA, we understand mining. One of the most critical; yet often overlooked; aspects of the maintenance function is the effective management of rotable components.

Maximize Asset Lifespan and Availability

Rotables are high-value, serviceable components that represent a significant investment. Properly tracking and managing these items is essential to:

Maximize asset life cycle
Optimize equipment uptime
Protect working capital
Enhance return on asset investment (ROI)

Yet many mining operations struggle to manage rotables effectively. The result is unnecessary downtime, wasted resources, and weakened asset performance.

take control

Common Challenges in Rotable Management

PSA commonly sees clients struggle with the boundless requirements of managing high value spares and serialized components. We have worked directly with global mining clients, learning from their biggest challenges, to create a rotable inventory management module that gives full visibility into your rotable inventory and the effectiveness of your components in operations.

Here are some of the most frequent issues we see in the field:

Lack of visibility into the location, usage history, or repair status of rotable parts
Idle inventory expensive components forgotten in storage
Capital tied up in redundant or excess rotable stock
Poor availability when components are needed due to ineffective planning
Unplanned downtime caused by missing, unserviced, or untracked rotables
Incomplete service history, limiting informed decision-making
Uninspected returns; parts re-enter service without proper QA
Disjointed processes across operations, maintenance, and supply chain

Lack of tracking

Missing location/status of rotables

No service history

Missing or incomplete maintenance data

Rotables stuck in warehouse

Idle high-value parts in storage

Untracked return cycles

Unmonitored send/return/ service loops

PSA Rotables Enhancement

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Integrated Rotable Management and Workflow

PSA’s Rotables solution transforms how you manage and maintain critical high-value components. By embedding real-time tracking, workflow automation, and lifecycle visibility, you gain complete control over your rotable inventory and performance.

What PSA’s Rotables Solution Delivers

Real-Time Serialised Tracking

Monitor the exact location and status of every rotable as it moves between assets, work sites, and warehouses.

Full Maintenance History

Monitor the exact location and status of every rotable as it moves between assets, work sites, and warehouses.

Automated Return & Refurbishment Workflows

Monitor the exact location and status of every rotable as it moves between assets, work sites, and warehouses.

Better Asset Availability & Control

Monitor the exact location and status of every rotable as it moves between assets, work sites, and warehouses.

Insight-Driven Reporting 

Monitor the exact location and status of every rotable as it moves between assets, work sites, and warehouses.

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PSA Rotable Process Workflow

Managing Rotables: Simple in Theory, Complex in Practice

At first glance, managing rotables seems straightforward: issue the part, track its use, repair it, and return it to stock. But in reality, every rotable component follows a unique and often complex lifecycle; spanning multiple locations, service vendors, inspections, and warranty conditions.

Without a robust, integrated system, data becomes fragmented. Parts go missing. Service records and turnaround times slip through the cracks. This complexity makes rotable management one of the most underestimated challenges in asset-intensive industries.

That’s why PSA has developed a structured, automated rotables workflow in Pronto Xi, giving you complete control over the lifecycle of every component and maximizing the value of both the rotable and the major asset it supports.

Plant Maintenance Stage

MaintenanceWork Order Raised

Materials Requisition

Spare Parts Warehouse

Pick Slip

Parts Issued

Maintenance Performed and Components Swap Out

Component Repair Stage

Repairs Warehouse

Repair job Raised

Parts Issued

Repair completed In the workshop or externally

Rotable Return

Return Pick Slip

Repaired part returned to be re-used

Transfer

Plant Maintenance Stage

MaintenanceWork Order Raised

Materials Requisition

Spare Parts Warehouse

Pick Slip

Parts Issued

Maintenance Performed and Components Swap Out

Component Repair Stage

Repairs Warehouse

Repair job Raised

Parts Issued

Repair completed In the workshop or externally

Rotable Return

Return Pick Slip

Repaired part returned to be re-used

Transfer

Extended Asset Lifespan: Proactive maintenance and traceability increase component life cycle and ROI.

Improved Operational Efficiency Automated workflows reduce delays and keep critical equipment running.

Smarter Decision-Making: Access full usage and repair records to support better planning and strategy.

Regulatory Compliance: Meet maintenance and reporting requirements with built-in audit trails and controls.

FAQs - Rotables Management

What are rotables, and how are they different from consumables?

Rotables are high-value, repairable components—like engines, pumps, or gearboxes—that can be reused after maintenance or refurbishment. In contrast, Consumables are used once and discarded (e.g., filters, gaskets). Rotables require lifecycle tracking, service history, and logistical control.

Why is rotable management important?

Rotables are high-value, repairable components—like engines, pumps, or gearboxes—that can be reused after maintenance or refurbishment. In contrast, Consumables are used once and discarded (e.g., filters, gaskets). Rotables require lifecycle tracking, service history, and logistical control.

Isn’t rotable management just a matter of tracking items in and out?

Rotables are high-value, repairable components—like engines, pumps, or gearboxes—that can be reused after maintenance or refurbishment. In contrast, Consumables are used once and discarded (e.g., filters, gaskets). Rotables require lifecycle tracking, service history, and logistical control.

What challenges are common when managing rotables?

Rotables are high-value, repairable components—like engines, pumps, or gearboxes—that can be reused after maintenance or refurbishment. In contrast, Consumables are used once and discarded (e.g., filters, gaskets). Rotables require lifecycle tracking, service history, and logistical control.

What kind of system is needed to manage rotables properly?

Rotables are high-value, repairable components—like engines, pumps, or gearboxes—that can be reused after maintenance or refurbishment. In contrast, Consumables are used once and discarded (e.g., filters, gaskets). Rotables require lifecycle tracking, service history, and logistical control.

Can rotables be tracked with a standard inventory system?

Rotables are high-value, repairable components—like engines, pumps, or gearboxes—that can be reused after maintenance or refurbishment. In contrast, Consumables are used once and discarded (e.g., filters, gaskets). Rotables require lifecycle tracking, service history, and logistical control.

How does systemising rotable management help reduce costs?

Rotables are high-value, repairable components—like engines, pumps, or gearboxes—that can be reused after maintenance or refurbishment. In contrast, Consumables are used once and discarded (e.g., filters, gaskets). Rotables require lifecycle tracking, service history, and logistical control.

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