Access the best thinking, right here. Have a question you don't see an answer to? Enquire now. Deon McHatton , 31 August 5 min read. Having spare parts on hand is a crucial aspect of manufacturing maintenance, as every plant needs to carry a certain amount of spares to be able to recover in the event of a failure. Spares holding represents capital expenditure on products that return no bottom line contribution.
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- Digital Inventory: How 3D Printing Lets Manufacturers Rely Less On Warehouses Of Stuff
- Spare parts
- Trim the fat from your spare-parts inventory
- Food Industry Storage Solutions
- The Importance of Spare Parts Inventories
- Spare Parts
- Using KPIs to Measure & Manage Your Spare Parts Inventory
- 7 Things to Consider for Successful Spare Parts Management
Digital Inventory: How 3D Printing Lets Manufacturers Rely Less On Warehouses Of StuffVIDEO ON THE TOPIC: Spare parts warehouse
The survey identifies plant maintenance management strategies and parts and component inventory practices, as well as how inventory is managed. Plant operations employees do more decision-making now 19 percent than a year ago 12 percent. Maintenance personnel still make the majority of the maintenance replacement decisions overall 45 percent , but they saw their role reduced significantly from the prior year 64 percent. More than 40 percent of food and beverage companies have changed their inventory practices.
Thirty percent of participants are reducing their replacement parts inventory and say cost is the main reason, followed by an effort to move to a just-in-time model or to dispose of obsolete parts. Twelve percent of respondents are increasing their inventory of replacement parts and components, with new equipment needs emerging as the primary reason. New equipment also helps manufacturers eliminate or decrease downtime. High-quality OEM replacement parts and components are selected 32 percent of the time when most parts are commodities with price as the determining factor when specifying requirements.
One-third of those surveyed say they buy OEM when most parts are commodities and where price is the determining factor. Almost one in eight says manpower shortages force plants to specify the highest-quality available part as a way to prolong mean time to failure.
Problems from non-OEM parts vary from not working as well compared to an OEM part to concerns that received parts may be counterfeit. One-fifth of participants say they avoid potential work stoppages and downtime by using only OEM parts.
Nearly 40 percent of respondents say less expensive non-OEM parts work just as well as their higher-priced counterparts. An equal number 40 percent says less expensive parts do not work as well as more expensive alternatives, and one-third report they have experienced premature machine failures with less expensive parts. Ninety percent of respondents consider the lifecycle cost of replacement parts as significant when making new equipment purchasing decisions.
Three in 10 companies say they always consider lifecycle costs of the replacement part or component in their purchasing decision, while six in 10 say sometimes they consider it. Replacement part ordering is automated in 75 percent of plants. Half of the companies report automating their ordering with system-generated purchase orders. Ten percent of respondents say they automate ordering with a direct link to a parts supplier or distributor, while another 11 percent rely on standardized hard copy purchase orders.
Regularly scheduled visual inspections are cited as the main maintenance replacement strategy implemented, selected more than half the time; the run-to-failure strategy is favored 20 percent of the time.
Additional strategies include a time-based or volume-based parts replacement schedule, automated measuring of parts and components, and predictive tools such as vibration analysis, thermal imaging and energy use or heat measurement. Two of every 10 respondents indicate no condition monitoring is done at their company.
Three maintenance repair operations MRO inventory practices are equally leveraged among companies this year: remanufacturing or re-engineering of parts onsite in a machine shop; vendor-managed inventory; and parts kits for routine maintenance. Central warehousing of common parts for use at multiple plant locations and consignment where the supplier owns the components are other, more common MRO practices.
A growing number of food and beverage facilities rely on less common types of MRO inventory practices 14 percent for as opposed to 4 percent reported a year ago.
Less than half 43 percent have implemented MRO cost-cutting strategies. However, inventory reduction and vendor-managed inventories are mentioned frequently among food and beverage companies that have implemented a cost-cutting strategy. Reduction of obsolete parts is an additional strategy. This website requires certain cookies to work and uses other cookies to help you have the best experience. By visiting this website, certain cookies have already been set, which you may delete and block.
Food Engineering logo. Inventory interests More than 40 percent of food and beverage companies have changed their inventory practices. Previous 1 2 Next.
Most organizations have a significant financial investment in spare parts maintenance, repair and operations MRO storeroom inventory. The remaining share of the inventory consists of critical spares and slow-moving, excess, or obsolete parts. Critical spare parts are items that have an excessively long order lead time, are one of a kind, or have an immediate effect on safety, the environment, or production. When a critical spare is put into service and the on-hand inventory level falls to zero, the risk factor rises very high. If another equipment failure were to occur that required this part, your facility would be in trouble.
The manufacturing systems that companies thrive on require more than lubrication and maintenance. They also require spare parts. Most manufacturing and processing companies keep an inventory of spare parts. However, small businesses should also consider creating a spare parts inventory as well.
Trim the fat from your spare-parts inventory
Many companies, large and small, have storerooms or warehouses containing inventory ready to ship directly to customers. Production departments typically report the number of units produced per man-hour worked, or the number of units produced per kilowatt hour. Measuring KPIs such as these allows companies to manage production of those units, thereby controlling cost. Maintenance departments, however, measure different parameters such as the number of Work Orders in backlog.SEE VIDEO BY TOPIC: How to Optimize Your Maintenance Spare Parts Inventory - Business Performance Improvement
Sauro Riccetti obtained a graduate diploma in electrical and electronic engineering and membership to the Society of Engineers London , then a postgraduate diploma and a master of science MSc degree in manufacturing engineering at the Open University UK. He continued his research studies on maintenance and process engineering applied to the food industry, receiving his doctor of philosophy PhD degree in manufacturing engineering from the School of Engineering and Design at Brunel University London. Riccetti has worked in the food industry for more than 30 years. His experience at Tetra Pak Italy and in holding several different positions including training manager, customer service director, and business development director, in addition to his involvement in improvement projects for the food industry, have enabled him to gain wide experience on maintenance and process engineering applied to the food industry. Riccetti lives in Modena, Italy, and can be contacted at sauro. Sauro Riccetti. Existing maintenance engineering techniques pursue equipment reliability with a focus on minimal costs, but in the food industry, food safety is the most critical issue. This book identifies how to ensure food product safety through maintenance engineering in a way that produces added value and generates real profits for your organization.
Food Industry Storage Solutions
Selo has its own in-house service team. This means that we can support you in case of faults, training courses and technical issues. Our service team can be deployed internationally and will meet you at your own site. Numerous national and international companies have been making use of this service for many years and appreciate our flexible deployment.
The Importance of Spare Parts Inventories
Supply chain management and the production and storage of spare parts represent something of a sticking point for the global manufacturing industry. Many of these parts will take up space for years, with some going unused but staying put just in case. Out-of-production original assemblies may become fully obsolete once parts are no longer in stock, leaving owners at a loss and needing to reinvest in wholly new products to replace something that may have only been impacted by one broken component that couldn't be replaced. A look inside a busy warehouse in the UK highlights physical storage needs. Many industries rely on physical inventory to meet aftermarket needs and have accordingly built up global supply and distribution networks. Automotive parts, for example, are produced in great quantities with the ubiquity of the personal vehicle creating great demand around the world for a variety of makes and models, each of which will eventually need some parts replaced due to wear and tear, accidents and impacts, or another end to useful component lifetime. The unpredictability of human behavior and what actually happens to vehicles in use means there is no perfect projection formula to ensure that the right stock of parts will be available as needed in helpful proximity to any given site of use. Storing parts for the possibility of their use requires a generally large physical footprint, as well as facility upkeep and the personnel to keep it running.
As a maintenance manager, your livelihood hinges on your ability to control maintenance costs and minimize production downtime. Whether you work in manufacturing or in the food and beverage industry, you need to protect the health of your equipment and take the necessary measures to ensure that your facility runs efficiently. One of the best ways to accomplish these goals is to develop a strategic spare parts management method to organize your spare parts. Below are eight best practices to help optimize your spare parts inventory. One of the greatest challenges facing inventory control specialists is tracking for excess or unused parts that are not included in a company's existing inventory control system. While it can be tempting to temporarily store these "one off" parts or components in a box in the corner, they should be assigned an official part number and added to your inventory control system. Learn which KPI's are the most important to measure.
Using KPIs to Measure & Manage Your Spare Parts Inventory
The survey identifies plant maintenance management strategies and parts and component inventory practices, as well as how inventory is managed. Plant operations employees do more decision-making now 19 percent than a year ago 12 percent. Maintenance personnel still make the majority of the maintenance replacement decisions overall 45 percent , but they saw their role reduced significantly from the prior year 64 percent.
7 Things to Consider for Successful Spare Parts Management
Life Cycle Engineering provides engineering solutions that deliver lasting results for private industry, public entities, government organizations and the military. Solutions Life Cycle Engineering is committed to helping you implement solutions that improve performance and meet your objectives. We develop our solutions and services to meet the specific challenges and requirements of a wide variety of organizations.
The function of a spare parts warehouse is to stock all critical inventory parts, material, and tools necessary to maintain and keep a manufacturing line up and operational. Often, spare parts warehouses are treated as a stepchild to the procurement or manufacturing of a business. Neglecting your spare parts warehouses will not benefit your business as they often must go through transitions to improve their support of growing production volumes. The inventory may include multiple levels of bill of material BOM and have parts, materials, and tools which are used across multiple pieces of machinery on the production line.
Пусть пройдут все двадцать четыре часа - просто чтобы убедиться окончательно. Сьюзан это показалось разумным. Цифровая крепость впервые запустила функцию переменного открытого текста; быть может, ТРАНСТЕКСТ сумеет взломать шифр за двадцать четыре часа. Но честно говоря, она в это уже почти не верила.