Here are the key steps in the repair order process according to the given priority rules: 1. Emergencies are addressed within 2 hours to prevent injury or serious damage. 2. Urgent issues are resolved within 24 hours to minimize disruption. 3. High priority routine repairs are completed within 7 days. 4. Lower priority routine repairs are done within 21 days. 5. Cyclical or planned routine repairs are bundled and addressed within 6 weeks to improve efficiency. The priority rules help ensure the most critical repairs are completed quickly while still addressing less urgent issues in a timely manner.

2.  is an interchangeable part that is kept in an
inventory and used for the repair or replacement
of failed parts.
 an important feature of logistics management and
supply chain management, often comprising
dedicated spare parts management systems.
 Example :-
 Cars(e.g.. Tires)

3.  Criticality analysis is a method for identifying
product or process criticality for the purpose of
prioritizing activities like design and maintenance
 Criticality is the combined measure of the failure
mode probability and the severity of its effects.

4.  It has been observed in many industries
that the non-availability of spare parts,
as and when required for repairs,
contributes to as much as 50% of the
total down time

6.  2. Non critical spares
-that have substitutes
-that can be made / purchased in short
notice
- that have high reliability
- without which machine can run

7.  Non-repairable Spares
Parts which fail can’t be repaired and
must be replaced with a new parts

8.  Repairable Spares
Parts which fail can be repaired and
be used back as spares

9.  Analytic hierarchy process
 find out relevant factors of the critical spare parts and
determine the relative importance
 Grey prediction model
 find a sequence of each element corresponding to
future dynamism, thereby developing prediction model
 Back-propagation network
 used as a tool for judging the predictability
 Moving average method
 The moving average (MA) is the mean of the previous
data sets used to perform CSP demand prediction

11.  The objective of spare parts
management is to ensure the
availability of spares for maintenance
and repairs of the plant and machinery
as and when required at an optimum
cost.
 Need a proper planning and control of
spare parts inventory.

12. Identify requirement
Procure parts
Initiate replacement
process
Reorder part
replacements
Complete administrative
tasks

13. Current
holdings are
monitored
Standard and
procedures and checked
relevant against levels
documentation determined
Each is obtained
holding by
location is procedures
checked as
to needs

14. Current
holdings are
matched
with need
Requests for
Checks are additional parts
made as to are made in
extra holdings accordance
in other with enterprise
locations procedures

15. • Need for spare parts is determined
• Data base is activated to check possible location of
specific parts required
• Arrangements are put in place to deploy the part to the
site where it is required
• Part is changed over with the faulty part
• Faulty part is recovered and disposed of or returned for
repair as determined by condition and enterprise policy

16. Relevant part request Delivery of replacement
(forms/documentation) is followed up on a
is completed and regular and ongoing
forwarded to the vendor basis (eg: phone call)
Reorder part replacement
Alternate spares are
sought where difficulties
(delay/no stock) are
experienced with
replacement

17. Checks are made to
ensure that all parts
are latest issue and
are compatible with
installed systems
and equipment
Regular audit of Relevant
stock holdings is documentation is
conducted in completed, signed
accordance with and forwarded to
enterprise policy the appropriate area
Complete
administrative
tasks

18. Helps us know the
Inventory is the total
precise number of items
amount of goods and/or
on the shelves and
materials contained in a
storage areas in order to
store or factory at any
place orders or control
given time.
losses

20. F N analysis
:
:
Items that :
Items that
are frequently Items that
are not
issued say are issued less
issuedused
more than than once a
for more than
once a month
2 years.
month.

21. H M L
Medium Cost (M)
High Cost (H) :
: Low Cost (L) :
Item whose unit
Item whose unit Item whose unit
value is very
value is of value is low
high
medium value

22. : A spare part will be termed vital, if on
account of its non-availability there will be very
high loss due to production downtime and/or a
very high cost will be involved if the part is
procured on emergency basis. In a process
industry, most spare parts for the bottleneck
machine or process will be of vital nature.For
example, bearings for a kiln in a cement plant will
be considered vital.
: A spare part will be considered essential
if, due to its non-availability, moderate loss is incurred.
For example, bearings for motors of auxiliary pumps will
be classified as essential.
: A spare part will be desirable if the
production loss is not very significant due to its non-
availability. Most of the parts will fall under this category.
For example, gaskets for piping connection

23. Definition
Process of restoring and maintaining
an equipment, machine , or system in
a serviceable condition.
Overhaul involves:
- partial or complete disassembly of the item,
- inspection to detect damaged, defective,
or worn parts,
- repair or replacement of such parts
- reassembly, testing, and trial-run prior to
returning the item to its full operating level

24.  Classes of Overhaul Work There are five classes of
equipment overhaul (A, B, C, D, and E). The class defines
the type and scope of work to be done on each
equipment by the overhauling activity. (Do not confuse
equipment overhaul with the term regular overhaul.)
 CLASS A OVERHAUL.—A class A overhaul includes
overhaul, repair, and/or modification; for example a
modification could be an Ordnance Alteration (ORDALT),
Special Program Alteration (SPALT), Ship Alteration
(SHIPALT), or a field change that will sustain or improve the
performance of a system or component to meet its most-
recent design and technical specifications. The end
product should be like new in appearance and operation.
 CLASS B OVERHAUL.—A class B overhaul includes overhaul
and repair that will restore the performance of a system or
component to its original design and technical
specifications. Modifications or alterations are not done
unless specified by the customer.

25.  CLASS C OVERHAUL.—A class C overhaul
includes only repair work on a system or
component specified by a work request or
work required to correct malfunctions specified
by the customer.
 CLASS D OVERHAUL.—A class D overhaul
includes work related to the open, inspect and
report type of work request. It is intended to be
diagnostic in nature and may require various
tests. It is normally associated with preoverhaul
test and inspection (POT& I).
 CLASS E OVERHAUL.—A class E overhaul
includes work required to incorporate all
alterations or modifications specified for a
system or component.

26. Definition
 A person or thing that take a place of
another esp. of one that has worn out,
broken down,etc

27.  WHY NEED REPLACEMENT??
 The cost for repair the equipment is more
expensive than the cost to replace the new
equipment.
 Equipment reach it life-cycle to work
efficiently. At that time the overhaul procedure
is no useful.
 Increasing operational effectiveness when the
equipment was replace with new equipment
even at the first, higher initial investment are
required.
 When the equipment presents an
unacceptable safety risk to the plant, plant
personnel or the environment
 Not meet the specification required by
customer. Means that the quality of the
product produced at low quality

28.  coffee roaster(Main Fan Replacement)
 To start, remove the Heat Guard Grills and Main Filter
as indicated in this image by the green arrows.
Loosen all four Phillips head screws (red arrows) which
hold the fan in place. Hold the fan against the
machine when removing the last screw.

29. Lower the fan, but take care not to stress the wires.

30.  Carefully pull the connector through the
back of the machine. Grasp the two halves
of the polarized connector and wiggle
them while pulling to separate them. As
seen here, the connector will only go back
together in one way.

31.  When replacing the fan push the wires and
connector through the back of the machine, and
place the wires as shown here. Be sure not to pinch
the wires when replacing the fan. Hold the fan in
place, be sure that it is aligned all the way around
and that the wires are not pinched, and then loosely
replace all for screws before tightening them. Do not
over-tighten the screws!

32.  Set of rules according to which actions
are generated in the repair order.
 It is assigned in customizing to the item
categories that are relevant for repairs
processing and is adopted in the repair
request item in the repair order.

33. CATEGORY AND DEFINITION RESPONSE TIME
PRIORITY
1 Emergency Failures or defects causing or likely to Within 2 hours
cause widespread disruption, injury to
person, serious damage to the
building, fabric, services, equipment or
property.
Emergency works take priority over all
other categories of work.
2 Urgent Failures or defects which do not Within 24 hours
present a serious risk of damage or
injury, but will cause considerable
disruption and inconvenience.
3 Routine(High Within 7 days
priority) Normal repairs which are unlikely to maximum
cause a high degree or inconvenience
4 Routine(Low priority) Within 21 days
or risk to any persons or property
maximum
5 Cylical(Planned As described in 3 and 4 above but can
routine) differed to enable work to be batched Within 6 weeks
and planned on regular basis