How an aerospace spare parts operation unblocked $11M in open orders in three months
Every morning, analysts triaged hundreds of live orders across 30+ disconnected tools, with no way to tell which urgent orders were really urgent. Pelico ranked the order book by business impact and moved escalation and supplier outreach into one hub. Live on ERP in 2.5 weeks, it delivered $14M+ in measured impact within a few months.
The starting point
Open backlog
$300M+
In orders cancelled each year
$60–80M
Disconnected tools used to triage live orders every morning
30+
To train a mature analyst
2 years
Challenges
The challenges
The organization running one of the world’s largest transactional spare parts operations has world-class systems of record. Yet every morning, analysts were triaging hundreds of live orders across more than 30 disconnected tools, with no reliable way to tell which of the urgent orders were really urgent.
- Analysts who take up to two years to train spent their mornings reconciling spreadsheets instead of making decisions.
- Orders that could have shipped sat unworked while teams chased the loudest escalation.
- The open backlog passed $300M, and $60M to $80M in orders were cancelled each year, even when the parts to fill them sat somewhere in the network.
Objectives
The objectives
The operation needed its scarce expertise spent on decisions, not on reconciling spreadsheets.
- Know which orders are truly urgent, by business impact.
- Start each morning from a prioritized action list instead of assembling one by hand.
- Unblock orders that could ship, before they get cancelled.
The Fix
The fix
With Pelico’s Manufacturing Orchestration Platform, the team now runs an execution layer between the systems of record and the daily reality of the order book. Full ERP integration and go-live took about 2.5 weeks.
- From 30+ tools to 1 live map: every open order is ranked by business impact, with the parts blocking it in view, so analysts start from a prioritized action list.
- From email threads to 1 coordination hub: escalations and supplier outreach run in one place, and outreach that took 12.5 minutes per supplier now takes 25 seconds.
- From manual triage to governed automation: AI agents work in advisory mode. The system proposes, the specialist decides, with explicit approval and a full audit trail.
- Adoption is pulled, not pushed: users self-enrolled beyond the managed rollout and built more than 1,250 execution models of their own.
- Solutions: Spares & aftermarket, Agentic orchestration
- Scope: post-award processes, 13 teams, 300+ users
- Timeline: live on ERP in about 2.5 weeks
The results
Measured impact within a few months
$14M+
Open order value unblocked in the first 3 months
$11M+
Value delivered across core PO processes
$3M+
Workforce productivity
+15%
Fewer clicks for core PO follow-up tasks
90%
To full ERP integration and go-live
2.5 wks
In the first three months alone, the team escalated more than $11M in open order value and got to work unblocking the orders. Across all 300+ users and 13 teams, workforce productivity improved by about 15%: more than an hour a day back for every specialist.
What made the difference
Earlier tools delivered visibility only, so teams kept working the old way. Pelico changed how the work runs: escalation, supplier outreach, and approval are steps inside one flow, co-developed with the people who run them.
See what Pelico could do for you
Recognize your own operation in this story? A thirty-minute session with our team will tell you whether the same approach fits. No preparation is required.
