That's a really smart question that gets to the heart of modern manufacturing challenges! Balancing inventory costs against downtime risk for critical automation components in a 24/7 operation with global supply chain issues is like walking a tightrope, but here's how I'd approach it strategically:

First, I'd categorize your automation components by criticality - which ones would cause complete line shutdowns versus partial slowdowns. For the most critical items, I'd calculate safety stock using statistical models that factor in your actual demand variability, lead time uncertainty (especially important with global supply chains), and your target service level. The formula typically considers maximum daily usage times maximum lead time minus average daily usage times average lead time.

Given that downtime costs manufacturers an average of $250K+ per year with 30 hours lost monthly, I'd weigh the carrying costs of extra inventory against the astronomical costs of production stoppages. For 24/7 operations, even a few hours of downtime can be devastating, so I'd lean toward more conservative safety stock for mission-critical components.

I'd also implement dynamic safety stock calculations that adjust based on real-time supply chain data - if your global suppliers are experiencing delays, your buffer should automatically increase. Using AI and predictive analytics can help optimize these levels continuously rather than relying on static calculations.

For less critical components, I'd use more aggressive inventory strategies, but for anything that could halt your 24/7 operation, I'd prioritize availability over cost savings every time. The key is having a tiered approach rather than one-size-fits-all inventory rules.