Mro spares opt-mrktng

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Mro spares opt-mrktng

  1. 1. THINKING BEYOND THE OBVIOUS MRO Spares Optimization Effectively managing spares inventory levels for efficientmaintenance planning and equipment reliability improvement 27 - 28 November 2012 Global Prospectus Training Centre, 366 Pretoria Avenue, Randburg “The art of progress is to preserve order amid change and to preserve change amid order” Alfred North Whitehead SETA Accreditation No. 2502
  2. 2. OVERVIEWSatisfactory uptime in a plant or service environment is necessary but not sufficient. Reducing the costs of ordering, storing andmaintaining spare parts is critical in reducing the cost of maintenance. Optimal spares control will not be possible without a clearunderstanding of the various events, actions and hurdles faced when planning, requesting, purchasing and receipting of spareparts. Inefficiencies in the spare parts supply chain are often the cause for the correct spare part not being supplied at the right timeand in the right quantity.Stock accuracy is a critical KPI in the service and maintenance environment, and even though internal audits are conducted inpreparation for an external audit, these audits, if not performed correctly, are not an accurate reflection of your stock count andvalue. How accurate is your spares audit really? Are you achieving 90 % accuracy in terms of the quantities that have been recordedin your system, and the stock quantities that really are there? And what is the value of this stock that hasn’t been accounted for?The replenishment of spares in inventory maintains the reliability level in your service or plant, if this is not followed it will result inoverstocking and deficiency. BENEFITS OF ATTENDING• Reducing the costs of ordering, storing and maintaining spare parts is critical in reducing the cost of maintenance• Analysing equipment trends and predicting essential spares requirements• Addressing risk management maintenance and equipment analysis• Anaylsing the numerous pitfall in cataloguing spares• Recognising common problems in conducting internal spares audits• Addressing elements that influence the decision to repair an item rather than replace it• Capitilising on the effective use of a maintenance management system• Improving interconnectivity between the business processes in the spare parts supply chain WHO SHOULD ATTEND• Purchasing / Procurement • Maintenance• Stores Managers • Operations• Warehouse / Inventory • Engineering• Spares Management • Quality Control• Service Planning Personnel • Finance• Material Planning EXPERT FACILITATORJeff Hollingdale Associate, ESCMJeff Hollingdale is an Associate of Contract Technical Services (CTS), a division of ESCM, a company focused primarily on the SupplyChain and Logistics sector. CTS specialises in maintenance and manufacturing related projects, with a particular focus on LeanManufacturing, TPM and Quality Practice (related to ISO 9000).Jeff is a certified Production and Inventory specialist (CPIM – APICS) and has consulted to a wide range of organizations to assistthem in projects ranging from defining Best Operating Practices, ‘waste’ reduction opportunities, Kanban / “Pull” manufacturingmethods, inventory/warehouse operations management, TPM, ‘lean’ maintenance practices and productivity improvement. Jeff haspublished a number of technical articles for industry related periodicals and presents as a speaker at a number of the conventionsin South Africa relating to Maintenance, Quality and the Supply Chain. GLOBAL PROSPECTUS TRAINING (PTY) LTD. Chief Executive O er - Dhevaraj Pillay Johannesburg - Tel: +27 11 781 6222 Fax: +27 11 781 6044 Marketing - m2@globalprospectus.co.za Auditors - Russell Bedford SA (Jhb) Inc. Pietermaritzburg - Tel: +27 33 391 4229 Fax: +27 33 391 5722 Design - www.designmaster.co.za (071 018 8355) Legal - DA Morris & Associates
  3. 3. DAY 1 Session One Establishing an effective strategy for cost and usage control in managing spare parts • Conceding the uptime in a plant or service environment is necessary but not sufficient • Reducing the costs of ordering, storing and maintaining spare parts is critical in reducing the cost of maintenance • Achieving optimal spares control will not be possible without reducing the cost of maintenance • Realising that the inefficiencies in the spare parts supply chain are often the cause for the incorrect spare part being supplied Session Two Questioning how accurate is your maintenance /service history Evaluating maintenance planning methods for effective spares replenishment • Implementing an effective maintenance strategy • Analysing equipment trends and predicting essential spares requirements • Analysing you equipment history by: - Failures - Downtime - Maintenance requirements Session Three Focusing on proven planned maintenance strategies • Reassessing maintenance approaches: - Addressing risk management maintenance and equipment analysis - Highlighting maintenance methods for critical spares determination • Investigating the accuracy of your maintenance history Practical Exercise: This hands on session will facilitate the knowledge exchange were delegates will work through an exercise on maintenance planning methods for effective spares replenishment after which your trainer will discuss potential problems and solutions along with input from the group Session Four Developing accurate cataloguing strategies • Deciding whether your maintenance EBOM (equipment bill of materials) is providing you with concise spares information • Anaylsing the numerous pitfall in cataloguing spares • Dissecting essential elements of an accurate EBOM • Defining and catagorising spare parts • Standardising spares descriptions • Eliminating spares exclusions and duplicate entries Session Five Performing an effective spares audit for increased stock accuracy • Utilising the ABCD analysis to accurately categorise spare parts • Developing effective cycle counting techniques • Recognising common problems in conducting internal spares audits • Tagging and disposing of obsolescent and redundant spares Practical case study session: In this practical exercise your training thus far will be enhanced by this case study session in which your trainer will refer to real-life examples of effective spares audit to illustrate, support and reinforce the concepts discussed so far.GLOBAL PROSPECTUS TRAINING (PTY) LTD. Chief Executive O er - Dhevaraj PillayJohannesburg - Tel: +27 11 781 6222 Fax: +27 11 781 6044 Marketing - m2@globalprospectus.co.za Auditors - Russell Bedford SA (Jhb) Inc.Pietermaritzburg - Tel: +27 33 391 4229 Fax: +27 33 391 5722 Design - www.designmaster.co.za (071 018 8355) Legal - DA Morris & Associates
  4. 4. DAY 2 Session Six Managing critical, frequently used and safety spares effectively There is mounting pressure on inventory and spares managers to hold the absolute optimal level of spares in their stores – financial managers will demand immediate answers to even the slightest increase in stock count. However, critical spares are crucial to ensure uninterrupted maintenance operations – a spare that is out of stock can result in a serious downtime situation. Frequently used, everyday spares need to be managed for minimum effort in accessing these spares, yet these spares still need to be accounted for in terms of consumption. In addition, the quantity required in safety spares is not easy to predict, which results in excessive costs tied up in safety spares. During this session you’ll establish how to identify, evaluate and make provision for critical, frequently used and safety spares. • Defining a ‘critical’ spare • Optimally applying maintenance history and usage patterns for critical spares • differentiating critical spares from safety/ security spares • Setting-up and controlling Point-of Use (POUS) spares and locations for standard frequently used items • Determining quantities of safety stock Round table discussion: Delegates will be given the platform to share their personal and organizational challenges faced in Managing critical, frequently used and safety spares Session Seven Dealing with rotables/repairable spares Rotable parts come with a unique set of challenges. The decision to repair a part involves more complex decisions than just that of slashing costs. Rotable parts must be carefully managed in order to ensure that maintenance really benefits from the process. A short-sighted approach to rotables may well increase production costs and escalate spares inventory levels. This session will look at the issue of rotables and how to manage them effectively. • Defining a rotable spare rather than a consumable spare • Addressing elements that influence the decision to repair an item rather than replace it • Investigating the business case for repairable spares (rotables) • Weighing up maintenance costs vs replacement costs • Elements to consider when managing repairable spares • Implementing methods to manage repairable spares Session Eight Taking control over your spare parts inventory; working with service/ asset management software, extracting information / reports to more effectively manage and plan service and maintenance spares. How to address service delivery in the maintenance supply chain. Any supply chain’s efficiency largely depends on the interconnectivity of the interrelated business processes. Yet, the different supply chain entities rarely operate in the synchronized manner that one would expect is necessary for optimal operational benefit. In this session, you will explore the spare parts supply chain and how to bring about a more coordinated effort for optimal spares control. • How to get the most out of the Materials Usage report • Achieving accurate data input • Assessing tried and tested data analysis methods using your inventory management system • Highlighting basic fundamentals that need to be in place in order to optimally manage maintenance spares • Assessing the efficiencies of the maintenance supply chain – where are the bottlenecks? • How to improve interconnectivity between the business processes in the spare parts supply chain • Improving service delivery between materials and maintenance management • Assessing the real effects of direct purchasing: the costs of single order items and non-stock items • Analyzing the pros and cons of maintenance outsourcing: what are the benefits and risk areas of outsourcing the supply of spare parts? Review of case studies of problems and solutions adopted : This highly interactive and concluding practical session, chaired by the trainer will expose attendees to real life case studies in managing MRO.GLOBAL PROSPECTUS TRAINING (PTY) LTD. Chief Executive O er - Dhevaraj PillayJohannesburg - Tel: +27 11 781 6222 Fax: +27 11 781 6044 Marketing - m2@globalprospectus.co.za Auditors - Russell Bedford SA (Jhb) Inc.Pietermaritzburg - Tel: +27 33 391 4229 Fax: +27 33 391 5722 Design - www.designmaster.co.za (071 018 8355) Legal - DA Morris & Associates
  5. 5. MRO Spares Optimization ONLY R749 27 - 28 November 2012 Per D eleg 0Registration Form Global Prospectus Training Centre, ex. VA ate, T. 366 Pretoria Avenue, RandburgGPW Marketing Fax Completed Registration Form To: +27 11 781 6044Company Name:Type of Business:Address:Tel: Fax: VAT Number:Delegate 1:Position: E-Mail:Delegate 2:Position: E-Mail:Delegate 3:Position: E-Mail:Delegate 4:Position: E-Mail:Delegate 5:Position: E-Mail:AUTHORISATION: Signatory must be authorised to sign on behalf of Company CREDIT CARDName: Cardholder’s Name: DETAILSPosition: Credit Card Number:Signature: Date: CVC No: Expiry Date:PAYMENT METHODS1. Bank Transfer - Global Prospectus Training (PTY) Ltd. 2. Credit card - Please fill in your credit card details above First National Bank: Randburg 3. Cheques - Made Payable to: Global Prospectus Training (PTY) Ltd. Account Number: 62109 270372 Branch Code: 254005TERMS & CONDITIONSThe following terms and conditions will apply: Substitutions Payment is required in full 5 days from date of invoice Delegates must inform Global Prospectus Training (PTY) Ltd in writing All payments to be made directly to Global Prospectus Training (PTY) Ltd. of any substitutions. No seats will be reserved, unless Global Prospectus Training (PTY) Ltd. receives a signed registration form. There is no charge for substitutions. Global Prospectus Training (PTY) Ltd. reserves the right, due to circumstances beyond our control, to change Global Prospectus Training (PTY) Ltd will not be held liable for incorrect speakers, program content, date & venue. Delegate details on Certi s, etc. in the event of substitutions being The signed registration form is a legally binding contract. made on the day of the conference. In the event of Global Prospectus Training (PTY) Ltd having to cancel or postpone an event due to circum-Cancellations stances beyond our control, delegates will be issued with a credit voucher,All cancellations will be subject to approval by the management of Global Prospectus Training (PTY) Ltd. - which may be used at another of our events.All cancellations made 7 days prior to date of the above mentioned event will be subject to a 50% cancellation fee.Cancellations made within 7 days of date of the above mentioned event, will be subject to a 100% cancellation fee. - Global Prospectus Training (PTY) Ltd will not be held liable for travel and accommoda -The will be no refunds or credit vouchers. tion costs. The conference fee includes: conference material, lunches and refreshments, but excludes travel & accommodation.GLOBAL PROSPECTUS TRAINING (PTY) LTD. Chief Executive O er - Dhevaraj PillayJohannesburg - Tel: +27 11 781 6222 Fax: +27 11 781 6044 Marketing - m2@globalprospectus.co.za Auditors - Russell Bedford SA (Jhb) Inc.Pietermaritzburg - Tel: +27 33 391 4229 Fax: +27 33 391 5722 Design - www.designmaster.co.za (071 018 8355) Legal - DA Morris & Associates

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