You are probably asking this because too many parts have been classified as critical, or because no one is confident that the current criticality ratings are accurate.
The reality is that not every important spare part is critical.
In fact, items that are critical for a machine to operate are not necessarily required as critical inventory.
This is counter-intuitive but also true.
And that distinction matters.
If everything is called critical, then the label stops being useful.
Criticality should help you make better decisions about stocking, review frequency, supplier management, maintenance support, and risk exposure.
The common mistake is allowing criticality to become an opinion.
In many organisations, parts are classified as critical because:
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the equipment is important,
maintenance says the part is needed,
the part has a long lead time,
the part is expensive,
the part has caused a problem before,
no one wants to take the risk of saying it is not critical.
Each of these factors may be relevant, but none of them automatically makes the part critical.
A part is not critical simply because it is expensive.
Nor is it critical simply because it belongs to critical equipment.
A better criticality decision separates consequence from emotion.
That means considering questions such as:
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What happens if the part fails and no spare is available?
Does the failure stop production, reduce capacity, create a safety risk, or breach compliance?
Is the item required to restore equipment function?
Can the part be repaired, sourced quickly, substituted, or bypassed?
Is the consequence based on current operating conditions?
Is the classification consistent across similar parts and assets?
Criticality should be a decision input, not a label applied casually.
Used properly, it helps determine which parts deserve attention, which parts require stronger controls, and which parts may not need to be stocked at all.
This topic is covered in the Foundation Playbook, which addresses not only why criticality matters and why it is often misunderstood, but also a comprehensive, yet easy to apply framework for determining criticality.
For teams, Foundations for Teams helps create a shared language so criticality is not driven by the loudest voice in the room.
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