spare parts management[1]
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Inventory Includes materials stocked in order to meet an unexpected
demand or distribution in the future
Any item which is lying idle
Types
Raw materials
Work-in-progress Finished goods
Spare parts
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Spare partsPart requirements for keeping owned equipment
in healthy operating condition by meeting repair
and replacement needs imposed bybreakdown,
preventive and predictive maintenance
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Differences between Production Parts & Spare
Parts Production Parts demand based on the
existence of marketdemand
derived demand basedon the customer demandfor the end product
Easier to forecast
Spare Parts
demand based on theequipment life cycle
Demand based on MTTF(mean time to failure)calculations
Difficult to forecast
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Classification of spares
Maintenance or Breakdown Spares
Insurance Spares Capital Spares
Rotable Spares
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Need for Spare Parts Management
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Managing Spare Parts ABC Analysis
VED Analysis
FSN Analysis
FMEA (Failure Mode Effect Analysis)
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VED AnalysisSpot welding machine
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Vital, Essential & Desirable SparesVital
Jump cable Kick less cable
Essential Desirable
Spring balance Pressure gauge
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Managing Spare Parts ABC Analysis
VED Analysis
FSN Analysis
FMEA (Failure Mode Effect Analysis)
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Risk Priority Number
In case of a 2-wheeler
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Component Severity Occurrence Detection RPN
Engine 10 6 6 360
Brake 9 4 7 252
Tires 10 3 8 240
Head light 5 3 9 135
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Production Asset
Operator Maintenance Engineer Spare Parts Manager
Error is
reported
Plan tasks &
check
Plan repair
dates
Receive purchase
order
Issue material & post goods
entry
Complete
repair
Release asset
Cancel unnecessaryparts
Re-procurement of
parts
Receive usage
statistics
Optimize usage stockwww.a2zmba.com
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Complexities in Spare Parts ManagementPredicting the demand -
Scheduled demand
Probabilistic demand
Carrying the Inventory -
For a manufacturing plant - held at two levels:
Plant level & Shop level
For a service organization - done as a part of multi-echelonservice networks
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Best practices in Spare Parts Management Multi-model based Inventory Management : Ability to plan
for parts based on variety of models such as criticalitymodels, cost models or movement models or a mix of
various models. Optimization model based on multi-echelon inventory: To
deploy inventory at various location based on need,criticality, service response etc.
A variety of forecasting algorithms : That can meet
different kinds of profiles such as intermittent demandmodels, attribution based demand models.
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