Spare parts control for maintenance purposes

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SPARE PART CONTROL

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Spare parts control for maintenance purposes

  1. 1. SUBMITTED BY: HIMALAYA KANWAR 1144834 D4 ME SEC B
  2. 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. 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. 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. 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. 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.
  7. 7. Service levels
  8. 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. 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.
  10. 10. Optimum stocking policy
  11. 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.

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