World class factory equipment spare parts program
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Transcript of World class factory equipment spare parts program
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Maintenance and Reliability Symposium
February 28, 2008
Houston Chapter SMRP Annual Symposium
World class spare parts management-Shobhit Bhutani
Dell Inc. Maintenance Manager
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Scope State of spare parts in industry Elements of a world-class spare parts
program Questions?
Agenda
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Human resources and effective people management- Heart of every successful operation
Equipment Standardization- Cohesive goal of maintenance and engineering organization
Scope- Topics not included
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Often ignored part of maintenance No faith on the spare parts personnel Cubby holes of spare parts spread all over the
field- technicians’ cars, field, near equipment & the stockroom
Spare parts- an afterthought of project work Insufficient infrastructure investment Time & management oversight required for a
successful spare parts program
State of spare parts in the industry
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Desired State
Transactional accuracy
Reliable & dependable- 1 central repository or controlled secondary repositories
Predictive spare parts requirements planned in
advance
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Elements of a world-class spare parts program
Dell Confidential
World class
Storeroom
Processes
CMMS-
Maintenance
& Engg. integration
High Spare parts
Availability
“Right parts in the right place at the
right time with optimum inventory”
“Right parts in the right place at the
right time with optimum inventory”
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High spare parts availability-1 (#of transactions in which spares not
available)*100/ (Total number of transactions)
High availability should be goal if downtime costs outweigh spare part costs
More onsite parts = More $ = Less Risk
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High spare parts availability-2
2 Key steps Control Introduction of new equipment and
spare parts - Engineering Change Control process incorporates spare parts
Perform spare parts gap analysis on Each unique piece of equipment List of spares reviewed by technicians Purchase of missing parts- $ spend based
on downtime risk
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High spare parts availability-3 Established equipment spare parts guidelines
BOMs, drawings, minimum spare parts required at install etc.
Establish templates
Spare parts description (nomenclature) standardization
Equipment type standardization
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CMMS-Maintenance & spares integration-1
Heart of maintenance
Spare parts integrated with work requests
Visibility to BOMs & drawings of equipment –procuring non available parts
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Equipment number Equipment Time open Time closed Elapsed Time Work Order#Description of Work
performedTechnician Rootcause
Consumed spare part code
Consumed spare part description
CV1001 Brake Conveyer 12/01/07 12:25pm 12/01/07 1:02pm 37 minutes 12200 Changed brake Tom Brake 14001 Linear BrakeBrake Conveyer 12/7/07 12:00 AM 12/7/97 12:43 AM 43 minutes 12456 Changed bearing Will Bearing 14325 Lube free brakeBrake Conveyer 12/10/07 4:56 PM 12/10/07 5:56PM 60 minutes 12459 Reset Bill 0 0 0
CMMS-Maintenance & spares integration-2
Sample CMMS spare parts report and benefits Usage tracking of spare parts Rootcause analysis Unit spare parts usage & cost of unit piece of
equipment Base information for prediction of spare parts
usage modeling
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Improved MTTR
Base of Transactional Accuracy
CMMS spare parts view Detailed Catalogue Integrated with Work orders Exploded view of equipment assemblies
CMMS-Maintenance & spares integration-3
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World-Class Storeroom Processes-1“Audit & verify processes”
Right parts in right locations.
Correct stock levels minimum stocked quantity & ordering quantities
Adequate stocking locations
Inventory accuracy periodic cycle counting
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Storeroom metrics- Periodic reviews $, usage, red flags Availability Shrinkage (lost parts) Stockout % (parts not available)
Rootcause fixes if issues discovered Min stock & ordering qty determined for each
part. Take assistance from statistical models Perpetual ordering of parts based on min
stock Below min stock report
World-Class Storeroom Processes-2
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Centralized location
Controlled access
Labeled shelves & bins Open Shelves - non-controlled parts Pallet racking - Heavy items Automated Carouse - Fast movers and controlled items
World-Class Storeroom Processes-3
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Open Shelving
Binstock parts- nuts, bolts, etc. Fasteners, Tools etc.
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Pallet Racking Storage
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Automated Storage Carousel
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QUESTIONS?
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BACKUP
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Spare parts engineering template
Equipment Name KVM SwitchDescription Model #Serial #BuildingLocation
Equipment Number
DescriptionStoreroom Location
Vendor Part Number
OEM Part # MFG. of Part Vendor
Qty in Machine
or System
Rec. Quantity
Lead Time (in weeks)
Unit of Measure
Unit Price
Extended Price
MIN Stock Level
MAX Stock Level
SPoF, Criticality of Part? (H,M,L)
`
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Standardized Part Description – Standard Commodity+ Unique Modifier
50 standardized Commodities
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Unique Modifiers for each commodities
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Descriptions Before and After
METROLOGIC SCANNERSCANNER - FIXED - LASER - METROLOGIC - METROLOGIC IS775-51
SEW-MAIN LINE MOTOR-W20DT71D4BMG05HR 1/4HP-87 RPM-3/4" Hollow Shaft W/230V BrakeMOTOR - GEARBOX - COMBO - 1.5HP - 230/460V - 2A - 1700:87RPM - 3/4" Hollow Shaft W/230V Brake MOTION INDUSTRIES W20DT71D4BMG05HR
SOLENOID SMC SY3240-5LOZSOLENOID - VALVE - 24VDC - 0.1-0.7 AMPS - SMC - SY3240-5LOZ
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Dell Confidential
Sample of future catalog vision
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Dell Confidential
Exploded View sample
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Dell Confidential
Reorder point analysis using lead time and usage
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References and Bibliography
Brown, Michael V. Managing Maintenance Storerooms, ISBN 0-7645-5767-X
Patton & Feldman Service Parts Handbook, ISBN 0-934623-73-2 Mobray, John. Reliability Central Maintenance, ISBN 0-8311-3044-
x, Industry Publications, 1992. Society of Automotive Engineers Reliability, Maintainability and
Supportability Handbook, ISBM 1-56091-244-87 SAE 1992. Automated Carousel units
http://www.donnegansystems.com/Automated_Storage_Products.html Pallet Racking
http://www.cisco-eagle.com/storage/rack/Palletrack/rack%20styles.htm