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Houston Chapter SMRP  Annual Symposium February 28, 2008 World class spare parts management Shobhit Bhutani Dell Inc. Maintenance Manager
Scope State of spare parts in industry Elements of a world-class spare parts program Questions? Agenda
Scope- Topics not included Human resources and effective people management-  Heart of every successful operation Equipment Standardization- Cohesive goal of maintenance and engineering organization
State of spare parts in the industry Often ignored part of maintenance No faith on the spare parts personnel Cubby holes of spare parts spread all over the field- technicians’ cars, field, near equipment & the stockroom Spare parts- an afterthought of project work Insufficient infrastructure investment Time & management oversight required for a successful spare parts program
Desired State Transactional accuracy Reliable & dependable- 1 central repository or controlled secondary repositories Predictive spare parts requirements planned in advance
Elements of a world-class spare parts program Dell Confidential World class  Storeroom Processes  CMMS-  Maintenance  & Engg. integration High Spare parts  Availability “ Right parts in the right place at the right time with optimum inventory”
High spare parts availability-1 (#of transactions in which spares not available)*100/ (Total number of transactions) High availability should be goal if downtime costs outweigh spare part costs More onsite parts = More $  = Less Risk
High spare parts availability-2 2 Key steps Control Introduction of new equipment and spare parts - Engineering Change Control process incorporates spare parts Perform spare parts gap analysis on Each unique piece of equipment List of spares reviewed by technicians Purchase of missing parts- $ spend based on downtime risk
High spare parts availability-3 Established equipment spare parts guidelines BOMs, drawings, minimum spare parts required at install etc. Establish templates Spare parts description (nomenclature) standardization Equipment type standardization
CMMS-Maintenance & spares integration-1 Heart of maintenance Spare parts integrated with work requests Visibility to BOMs & drawings of equipment –procuring non available parts
CMMS-Maintenance & spares integration-2 Sample CMMS spare parts report and benefits Usage tracking of spare parts Rootcause analysis  Unit spare parts usage & cost of unit piece of equipment Base information for prediction of spare parts usage modeling
CMMS-Maintenance & spares integration-3 Improved MTTR Base of Transactional Accuracy CMMS spare parts view Detailed Catalogue Integrated with Work orders Exploded view of equipment assemblies
World-Class Storeroom Processes-1 “ Audit & verify processes” Right parts in right locations.  Correct stock levels  minimum stocked quantity & ordering quantities Adequate stocking locations  Inventory accuracy  periodic cycle counting
World-Class Storeroom Processes-2 Storeroom metrics- Periodic reviews $, usage, red flags Availability Shrinkage (lost parts) Stockout  % (parts not available) Rootcause fixes if issues discovered Min stock & ordering qty determined for each part. Take assistance from statistical models Perpetual ordering of parts based on min stock  Below min stock report
World-Class Storeroom Processes-3 Centralized location Controlled access Labeled shelves & bins Open Shelves - non-controlled parts Pallet racking - Heavy items  Automated Carouse - Fast movers and controlled items
Open Shelving Binstock parts- nuts, bolts, etc. Fasteners, Tools etc.
Pallet Racking Storage
Automated Storage Carousel
QUESTIONS?
BACKUP
Spare parts engineering template
Standardized Part Description – Standard Commodity+ Unique Modifier 50 standardized Commodities
Unique Modifiers for each commodities
Descriptions Before and After METROLOGIC SCANNER SCANNER - FIXED - LASER - METROLOGIC - METROLOGIC IS775-51 SEW-MAIN LINE MOTOR-W20DT71D4BMG05HR 1/4HP-87 RPM-3/4" Hollow Shaft W/230V Brake MOTOR - GEARBOX - COMBO - 1.5HP - 230/460V - 2A - 1700:87RPM - 3/4" Hollow Shaft  W/230V Brake MOTION INDUSTRIES W20DT71D4BMG05HR SOLENOID SMC SY3240-5LOZ SOLENOID - VALVE - 24VDC - 0.1-0.7 AMPS -  SMC -  SY3240-5LOZ
Sample of future catalog vision Dell Confidential
Exploded View sample Dell Confidential
Reorder point analysis using lead time and usage Dell Confidential
References and Bibliography Brown, Michael V.  Managing Maintenance Storerooms , ISBN 0-7645-5767-X Patton & Feldman  Service Parts Handbook,  ISBN 0-934623-73-2 Mobray, John.  Reliability Central Maintenance , ISBN 0-8311-3044-x, Industry Publications, 1992. Society of Automotive Engineers  Reliability, Maintainability and Supportability Handbook , ISBM 1-56091-244-87 SAE 1992.  Automated Carousel units http://www.donnegansystems.com/Automated_Storage_Products.html Pallet Racking http://www.cisco-eagle.com/storage/rack/Palletrack/rack%20styles.htm

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World class factory equipment spare parts program

  • 1. Houston Chapter SMRP Annual Symposium February 28, 2008 World class spare parts management Shobhit Bhutani Dell Inc. Maintenance Manager
  • 2. Scope State of spare parts in industry Elements of a world-class spare parts program Questions? Agenda
  • 3. Scope- Topics not included Human resources and effective people management- Heart of every successful operation Equipment Standardization- Cohesive goal of maintenance and engineering organization
  • 4. State of spare parts in the industry Often ignored part of maintenance No faith on the spare parts personnel Cubby holes of spare parts spread all over the field- technicians’ cars, field, near equipment & the stockroom Spare parts- an afterthought of project work Insufficient infrastructure investment Time & management oversight required for a successful spare parts program
  • 5. Desired State Transactional accuracy Reliable & dependable- 1 central repository or controlled secondary repositories Predictive spare parts requirements planned in advance
  • 6. Elements of a world-class spare parts program Dell Confidential World class Storeroom Processes CMMS- Maintenance & Engg. integration High Spare parts Availability “ Right parts in the right place at the right time with optimum inventory”
  • 7. High spare parts availability-1 (#of transactions in which spares not available)*100/ (Total number of transactions) High availability should be goal if downtime costs outweigh spare part costs More onsite parts = More $ = Less Risk
  • 8. High spare parts availability-2 2 Key steps Control Introduction of new equipment and spare parts - Engineering Change Control process incorporates spare parts Perform spare parts gap analysis on Each unique piece of equipment List of spares reviewed by technicians Purchase of missing parts- $ spend based on downtime risk
  • 9. High spare parts availability-3 Established equipment spare parts guidelines BOMs, drawings, minimum spare parts required at install etc. Establish templates Spare parts description (nomenclature) standardization Equipment type standardization
  • 10. CMMS-Maintenance & spares integration-1 Heart of maintenance Spare parts integrated with work requests Visibility to BOMs & drawings of equipment –procuring non available parts
  • 11. CMMS-Maintenance & spares integration-2 Sample CMMS spare parts report and benefits Usage tracking of spare parts Rootcause analysis Unit spare parts usage & cost of unit piece of equipment Base information for prediction of spare parts usage modeling
  • 12. CMMS-Maintenance & spares integration-3 Improved MTTR Base of Transactional Accuracy CMMS spare parts view Detailed Catalogue Integrated with Work orders Exploded view of equipment assemblies
  • 13. World-Class Storeroom Processes-1 “ Audit & verify processes” Right parts in right locations. Correct stock levels minimum stocked quantity & ordering quantities Adequate stocking locations Inventory accuracy periodic cycle counting
  • 14. World-Class Storeroom Processes-2 Storeroom metrics- Periodic reviews $, usage, red flags Availability Shrinkage (lost parts) Stockout % (parts not available) Rootcause fixes if issues discovered Min stock & ordering qty determined for each part. Take assistance from statistical models Perpetual ordering of parts based on min stock Below min stock report
  • 15. World-Class Storeroom Processes-3 Centralized location Controlled access Labeled shelves & bins Open Shelves - non-controlled parts Pallet racking - Heavy items Automated Carouse - Fast movers and controlled items
  • 16. Open Shelving Binstock parts- nuts, bolts, etc. Fasteners, Tools etc.
  • 22. Standardized Part Description – Standard Commodity+ Unique Modifier 50 standardized Commodities
  • 23. Unique Modifiers for each commodities
  • 24. Descriptions Before and After METROLOGIC SCANNER SCANNER - FIXED - LASER - METROLOGIC - METROLOGIC IS775-51 SEW-MAIN LINE MOTOR-W20DT71D4BMG05HR 1/4HP-87 RPM-3/4" Hollow Shaft W/230V Brake MOTOR - GEARBOX - COMBO - 1.5HP - 230/460V - 2A - 1700:87RPM - 3/4" Hollow Shaft W/230V Brake MOTION INDUSTRIES W20DT71D4BMG05HR SOLENOID SMC SY3240-5LOZ SOLENOID - VALVE - 24VDC - 0.1-0.7 AMPS - SMC - SY3240-5LOZ
  • 25. Sample of future catalog vision Dell Confidential
  • 26. Exploded View sample Dell Confidential
  • 27. Reorder point analysis using lead time and usage Dell Confidential
  • 28. References and Bibliography Brown, Michael V. Managing Maintenance Storerooms , ISBN 0-7645-5767-X Patton & Feldman Service Parts Handbook, ISBN 0-934623-73-2 Mobray, John. Reliability Central Maintenance , ISBN 0-8311-3044-x, Industry Publications, 1992. Society of Automotive Engineers Reliability, Maintainability and Supportability Handbook , ISBM 1-56091-244-87 SAE 1992. Automated Carousel units http://www.donnegansystems.com/Automated_Storage_Products.html Pallet Racking http://www.cisco-eagle.com/storage/rack/Palletrack/rack%20styles.htm