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.
