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Spare Part Criticality Index

Criticidad

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Carlos Jose Sibaja Cardozo
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85 views

Spare Part Criticality Index

Criticidad

Uploaded by

Carlos Jose Sibaja Cardozo
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
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1.

Criticality assessment

The evaluation of spare parts is carried out according to four criteria:


• Impact on production.
• Probability of failure.
• Delivery or repair time.
• Cost of acquisition or production.
Based on the product of the production impact scores and the failure probability scores, the risk of failure of the
spare part is assessed according to Table 1.
Table 1.
Calculation of failure risk indicator
Probability of failure
Low High
Risk of failure Low Low Medium
probability of failure Frequent
Failure unlikely > 1 Frequent malfunctions 3
6 months. up to 1 malfunctions more
year months ≥ 6 months
year than 3 months.
Minimum
does not cause 1 1 2 2
equipment shutdown
Impact on production

Medium
Stop production <2:00 1 2 3 3
h.
Critical
2 hours <production 2 3 4 4
stop <8 hours
Strategic
production shutdown > 3 4 4 4
8 hours

Based on the product of the delivery time points for the spare part (repair) and the cost points (manufacturing)
of the spare part, the delivery time/cost of the spare part is estimated according to Table 2.
Table 2.
Calculation of delivery time/cost indicator
Purchase cost
Delivery time / cost
< 5 k$ from 5 to 20 k$ from 20 to 50 k$ > 50 k$.
Up to 4 weeks (up to 30 days) 1 1 2 2
Delivery
(repair)

From 4 to 8 weeks (30-60 days) 1 2 3 3


time

From 8 to 16 (60-120 days) 2 3 4 4


Over 16 weeks (over 120 days) 3 4 4 4

Based on the product of the failure risk scores and the delivery time/cost points of the spare part, the criticality
indicator of the spare part is assessed according to Tables 3 and 4
Table 3.
Calculation of criticality index
Delivery time/cost
Criticality index (Quantity Stock)
1 2 3 4
1 QS0 QS0 QS1 QS1
Risk of
failure

2 QS0 QS1 QS2 QS2


3 QS1 QS2 QS3 QS3
4 QS1 QS2 QS3 QS3
Table 4.
Description of the criticality indicator
Spare part
criticality Criticality level Requirements for creating an emergency stock
index
Not a critical spare part Zero stock in warehouses, maintenance and repair planning engineers together
QS0 Lack of a spare part on site does with the supply service need to have several suppliers and the ability to order
not affect the operation of the spare parts on the required date
process
Not a critical spare part It is necessary to review the stock or clarify the amount of stock; maintenance
QS1 The absence of a spare part leads and repair planning engineers, together with supply services, need to work out
to a process stop for less than 2 the list of supplies with the delivery being completed on time.
hours
Critical spare part Must be in stock and unified for different pieces of equipment. In case of
QS2 The absence of a spare part leads decommissioning from emergency stock, it must be immediately purchased
to unscheduled downtime of the
process from 2 to 8 hours
Strategic spare part The lack of a spare part will have serious consequences for production.
QS3 Lack of spare parts leads to Always have one spare part available.
unscheduled process downtime
for more than 8 hours

2. Ranking and analysis of obtained data

To obtain data on the criticality of spare parts from which it is necessary to form an emergency stock, the obtained
criticality result is ranked from QS3 to QS0, after which QS0 and QS1 are excluded from the list, but if necessary, can be
considered and included in the list in agreement with the engineering director.
The sorted list for emergency stock QS3 to QS2 is ranked by:
• Criticality class from AA to A.
• Risk of failure from 4 to 1.
The received data is analyzed by the maintenance planning engineer for compliance with the emergency stock
list obtained after ranking:
• At the beginning of the list, all spare parts comply with QS3 – AA – risk of failure 4
• The next spare part on the list is QS3 – AA – risk of failure 3
• The next spare part on the list is QS3 – A – risk of failure 4
• The next spare part on the list is QS2 – AA – risk of failure 4
• The next spare part on the list is QS2 – AA – risk of failure 3
• The next spare part on the list is QS2 – A – risk of failure 4
• The next spare part on the list is QS2 – A – risk of failure 3
Next, in the same order, spare parts with failure risks 2 and 1.

3. Final development of an emergency spare parts stock plan

The list obtained after ranking is sent to technical managers to set a priority group for replenishing the emergency
stock.
The number of priority groups is calculated based on the annual budget for emergency spare parts stock, the cost
of spare parts and is calculated using the formula (P*Q)1+(P*Q)2+(P*Q)x / B, where
P – cost of the spare part.
Q – the number of spare parts required in one position of the emergency stock list.
1; 2; x - one position in the emergency stock list.
B - the average amount of the annual emergency stock budget.
After the technical managers have completed the prioritization of emergency stock replenishment, the
maintenance planning engineer analyzes the results obtained in terms of compliance of the positions with the annual
emergency stock budget and sets the planned year of replenishment of the emergency stock for each position.
The resulting list of emergency stock is agreed upon with the heads of business processes of the engineering
directorate, the deputy director of engineering, the director of engineering and approved by the general director of the
enterprise.
Based on the approved list, the planning engineer, together with the reliability engineer, annually draws up a plan
for replenishing the emergency stock of spare parts.

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