Scribd
Upload
1K views8 pages

Spare Part Management

The document discusses spare parts management and control methods. It recommends determining which items to stock based on past usage and failure records. It then describes four common storage control methods: 1) Order point method, 2) Double-bin method, 3) Packaging method, and 4) Fixed inventory level method. Each method triggers reorders at different inventory levels or time periods to maintain adequate stock levels in a cost-effective manner. Visual controls are also emphasized for easy identification of parts.

Uploaded by

Naga Chaitanya
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
1K views8 pages

Spare Part Management

The document discusses spare parts management and control methods. It recommends determining which items to stock based on past usage and failure records. It then describes four common storage control methods: 1) Order point method, 2) Double-bin method, 3) Packaging method, and 4) Fixed inventory level method. Each method triggers reorders at different inventory levels or time periods to maintain adequate stock levels in a cost-effective manner. Visual controls are also emphasized for easy identification of parts.

Uploaded by

Naga Chaitanya
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 8

Spare Parts Management

Concept of Spare Parts Control

Carry out following most efficient decisions in order to carry out Planned
maintenance activities.
What items?

Decide what items to be stocked

What quantity?

Decide maximum and minimum stock levels

What control method?

Purchasing --- order point, order


quantity
Storage – “Visual control”
SPAREPARTS
SPARE PARTS MANAGEMENT
MANAGEMENT
Suggested flow of activities

List down all change parts LINE / M/C / Sub-Assembly / Part wise

❖ Check Past records of Failures.


Decide on MTBF ❖ Calculate MTBF for each part.
❖ Consider the Supplier’s suggestions.
❖ Take inputs from other sources
❖ Check Past records of Failures & MTBF.
Decide on MIN / MAX for Parts / ❖ Check the Lead time
Items to be stored ❖ Decide MIN / MAX Inventory

Use Visual Controls Extensively

STANDARDIZE THE PARTS


The Keywords for Seiton (2nd S)

1. BEND FREE 5. CLIMB FREE

2. STRETCH FREE 6. COUNT FREE (DO VISUALIZATION)

3. MIN / MAX 7. SEARCH FREE

4. DUST FREE 8. FIRST IN FIRST OUT (FIFO)


Visual Management
Engineering items
Example of Classification of Materials Used for Maintenance

Items used for


production
Die, roll jigs
Cutting tip, tool
Others Analytical instrument – filler etc

Non-stocked items
Items used for
maintenance

Spare equipment Change gear, reduction gear, pump, fan, motor etc
Pulley gear, impellers etc.
Equipment parts Guide roller, special oven, heating element etc.
Stocked items

Commercially available Bolt, nut, belt, chain, sealing component, pneumatic


common parts and hydraulic devices and component,
Piping component, wiring component, electrical parts.
Commercially available Steel pipe, electrical wire, oven materials,
common materials welding materials
fatty oils, paint etc.
Tools Spanner, file, cutting tip, jig etc.
Consumables Waste cloth, paper, washing oil etc
How to Determine What items should be stocked
Check Items
• Check past usage records
• Check if there will be future equipment
• Materials changes in equipment or parts
• Check if there are unexpected failures
• Check level of repair and maintenance techniques

Possible to Fix consumption Impossible to Fix consumption


Possible to forecast replacement Impossible to schedule consumption due
period by monitoring wear and tear to sporadic failure or other reasons

Annual usage
Unit price is cheap Unit price is expensive
Less than More than
Consider
X times X times
stock-out loss
Stocked Stock-out
items loss is High Stock-out
loss is Low

Non-stocked items Non-stocked items


Storage Control Method
Control Method and Description Order Point and Order Quantity Characteristics

Inventory Level
1. Order Point Method Order Point Basic form of fixed order
When inventory level reaches When inventory level reaches P quantity method. This method
the predetermined level (order D can be applied to the parts of

Q
small articles for which quantity
point P), order pre-determined P
of consumption is relatively

mm
quantity. Plan to receive Order Quantity stable.
ordered materials when it reaches Standard order quantity (Q)
minimum inventory level m. Time
2. Double-Bin Method Order Point This is a very popular control
Place two bins (Containers). When Start When one bin has become method. Almost all the
one bin has become empty, order empty. companies implement it. This
Halfw ay method is suitable if we store
the same quantity as in other bin. large quantities of low cost
Order point Order quantity materials such as bolts and
Order quantity Same quantity as in other bin
Empty nuts.
Loose
3. Packaging Method Order Point This is the most economical
inventory
Package order point quantity of inventory When all loose inventory has method. It can be applied to
and store it with loose inventory. Start been consumed low-value materials that have
Consume all loose inventory first till small ratio in total maintenance
packaged inventory has to be opened expenses.
to be consumed. Place an order Order Quantity
Order point
upon opening the package. Same quantity as in the
OPEN
Order card package
4. Fixed inventory level method Order Point This method is to keep certain
Fixed quantity of inventory at all
Order the consumed quantity 1 2 3 inventory
When inventory has been
whenever inventory is consumed level consumed. times. It is not economical due
is 3 pieces Order Quantity to frequent ordering but it
Out of storage ensures certain inventory level.
Consumed quantity only It can be applied to machines,
Consumption Order 1 piece jigs etc that involves drawings.

You might also like