際際滷

際際滷Share a Scribd company logo

Spare parts control for maintenance purposes

Download as PPTX, PDF
Himalaya Kanwar
Himalaya Kanwar

This document discusses spare parts management and outlines an approach for establishing an effective spare parts inventory system. It identifies typical characteristics of spare parts like high numbers and varieties, erratic consumption patterns, and sourcing constraints. The proposed approach includes creating a comprehensive spare parts list, classifying parts by criticality, and setting optimal reorder levels, safety stocks, and preservation plans based on factors like cost and usage frequency. The conclusion emphasizes treating spare parts management as a separate discipline, ensuring cross-functional cooperation, and involving engineers to properly assess requirements and optimize the inventory.

1 of 11
SUBMITTED BY: HIMALAYA KANWAR 1144834 D4 ME SEC B
Typical Characteristics of Spares Large in numbers and varieties Absence of Specifications Erratic consumption / No pattern Sourcing constraint High Prices High / non moving Inventory due to above parameters Requirement of Large Space and preservation Difficult to dispose off
Initial Approach Initial Approach Comprehensive List With details of Equipment and Spares Estimate Requirements based on past experience for similar equipments Classify Criticality of Equipments Classify Spares as Vital, Essential, Desirable Identify Insurance Spares Identify High Cost Spares Identify Durable and Consumable Spares
Inventory management Decide Frequency for review of Spares for critical Equipments Based on VED classification and cost of Spares, decide optimum safety stocks Fix min, max and reorder levels for consumable spares For durable spares, MRP data to be reviewed by competent engineers to assess requirements Insurance spares requirement to be initiated by user and reviewed at high levels Preservation plan and activity to be chalked out for durable and insurance spares
Operational Approach: Adopt Standardization as follows : Use Standard drives and couplings Use standard fasteners with maximum interchangeability Avoid fine threaded fasteners wherever possible. Instead use standard threads with lock washers. Establish standard range of lubricants for the entire plant. Use standard structural shapes ,bearings and belts. Use standard pipes and tube fittings. Replace with standard parts whenever non standard parts become defective.
Procurement strategy: Among various categories like Routine, Leverage, Bottleneck and Critical ,Spare parts fall into category of Bottleneck. Hence we should have close relationship with suppliers I.E OEMS/Alternate Sources.
Service levels
Safety Stocks: Safety stocks pertaining to different service levels is calculated as K^m where K is a constant with various values ranging from 0.7 to2.3 to give service levels from 75% to 99% Critical, cheap and frequently used items will require higher assurance level and hence higher safety stocks Non-Critical, expensive and slow moving parts will have low safety stocks.
Categorization of Spares Preventive maintenance spares-such as filter cartridge, rubber parts etc. These are known as programmed spare parts. Items with fairly steady and high usage. Short life items like bulbs, fuses, V-belts, bearings, switches etc. The aggregate quantity based on number of machines to be worked out. Low and irregular usage items. Long life items having fractional usage even annually. Items required for over-haul. Requirement per machine per over-haul.
Optimum stocking policy
Conclusion: Spare parts Management is to be treated as separate discipline from normal Inventory Management. Close cooperation and coordination among Operations, maintenance and Supply departments is essential to achieve optimum inventory levels. Top Management support and encouragement for calculated risk taking and innovation is a must for sustained improvement. Involvement of smart and knowledgeable engineers for assessment of requirements, usage/disposal of non-moving spares, identification of interchangeability of spares, development of drawings for source development and preservation norms.

More Related Content

Spare parts control for maintenance purposes

  • 1. SUBMITTED BY: HIMALAYA KANWAR 1144834 D4 ME SEC B
  • 2. Typical Characteristics of Spares Large in numbers and varieties Absence of Specifications Erratic consumption / No pattern Sourcing constraint High Prices High / non moving Inventory due to above parameters Requirement of Large Space and preservation Difficult to dispose off
  • 3. Initial Approach Initial Approach Comprehensive List With details of Equipment and Spares Estimate Requirements based on past experience for similar equipments Classify Criticality of Equipments Classify Spares as Vital, Essential, Desirable Identify Insurance Spares Identify High Cost Spares Identify Durable and Consumable Spares
  • 4. Inventory management Decide Frequency for review of Spares for critical Equipments Based on VED classification and cost of Spares, decide optimum safety stocks Fix min, max and reorder levels for consumable spares For durable spares, MRP data to be reviewed by competent engineers to assess requirements Insurance spares requirement to be initiated by user and reviewed at high levels Preservation plan and activity to be chalked out for durable and insurance spares
  • 5. Operational Approach: Adopt Standardization as follows : Use Standard drives and couplings Use standard fasteners with maximum interchangeability Avoid fine threaded fasteners wherever possible. Instead use standard threads with lock washers. Establish standard range of lubricants for the entire plant. Use standard structural shapes ,bearings and belts. Use standard pipes and tube fittings. Replace with standard parts whenever non standard parts become defective.
  • 6. Procurement strategy: Among various categories like Routine, Leverage, Bottleneck and Critical ,Spare parts fall into category of Bottleneck. Hence we should have close relationship with suppliers I.E OEMS/Alternate Sources.
  • 8. Safety Stocks: Safety stocks pertaining to different service levels is calculated as K^m where K is a constant with various values ranging from 0.7 to2.3 to give service levels from 75% to 99% Critical, cheap and frequently used items will require higher assurance level and hence higher safety stocks Non-Critical, expensive and slow moving parts will have low safety stocks.
  • 9. Categorization of Spares Preventive maintenance spares-such as filter cartridge, rubber parts etc. These are known as programmed spare parts. Items with fairly steady and high usage. Short life items like bulbs, fuses, V-belts, bearings, switches etc. The aggregate quantity based on number of machines to be worked out. Low and irregular usage items. Long life items having fractional usage even annually. Items required for over-haul. Requirement per machine per over-haul.
  • 11. Conclusion: Spare parts Management is to be treated as separate discipline from normal Inventory Management. Close cooperation and coordination among Operations, maintenance and Supply departments is essential to achieve optimum inventory levels. Top Management support and encouragement for calculated risk taking and innovation is a must for sustained improvement. Involvement of smart and knowledgeable engineers for assessment of requirements, usage/disposal of non-moving spares, identification of interchangeability of spares, development of drawings for source development and preservation norms.