Spare Parts Management

Course Outline

INTRODUCTION

• Objectives
• Results Oriented Reliability and Maintenance
• Workflows/process
• Common Definitions

MASTER DATA

• What is it?
• Relevant information fields
• Meaningful descriptions
• Naming conventions
• Other fields Specifications
• Information for future use
• How to gather master data information
• How to maintain master data information

SPARE PARTS CLASSIFICATIONS

• Equipment criticality
• What it is
• How to determine
• Tool to use
• Critical
• Insurance
• Low risk
• Non-stock

SPARE PARTS STOCKING DECISIONS

• What impacts decisions

INVENTORY LEVELS

• For new parts
• Existing inventory
• Maximums and minimums
• Reorder points
• Safety stock
• Economic order quantity
• Reserving parts

STOREROOM ORGANIZATION

• Parts bin locations Vertical storage
• Open racks
• Closed cabinets
• Format numbering
• Centralized vs. Satellite Stores
• Parts issuing areas
• Parts receiving areas
• Part kitting area
• Housekeeping and parts cleanliness
• Vending machines
• High density stores

INVENTORY CONTROL

• Parts issuing
• Parts receiving
• Parts returning
• Parts requisitioning/purchasing
• Access to stores
• Physical inventory
• Cycle count
• 100% count
• IDCON I.R.A.
• Stock-outs

REPAIRABLE SPARES

• Process
• Purchasing/Vendor relations
• How to manage in CMMS

QUALITY PROGRAM

• Parts receiving process
• Storage Bet practices
• Bearings
• Electrical/electronic components
• Lubricants

PREVENTIVE MAINTENANCE PROGRAM

• Motors
• Gearboxes
• Rotating spares

REPORTS, KPIS AND DATA ANALYSIS

• Parts catalogue
• Usage trend
• Fast Movers

INVENTORY OPTIMIZATION

• Duplicate parts
• Parts movement
• Fast
• Slow
• Very Slow
• No
• Obsolescence
• How to identify
•  Managing

BASIC ACCOUNTING

• Expense
• Parts in inventory
• Parts bought for capital projects

PURCHASING AND CONTRACTING

• Who’s responsible Approval process P Cards
• Supplier Contracts

VENDOR RELATIONSHIPS

• Team vendor concept
• Consignment
• Vendor managed inventory (VMI)