2. What are Spares Parts
Spare parts are extra parts that are near to a
functioning part
When a machine has problems, spare parts
can be used to replace broken /damaged parts
so that the machine can function.
Example :-
power module (eg. Transformer)
Electronic parts (eg. Integrated components / semi-
conductors and etc.
3. What is Criticality Assessment
Give an indication of which items of plant are
most critical to your process.
Good idea to do a criticality assessment so
everybody involved on your plant knows how
crucial any single item of plant is to the
process and how quickly to act when
diagnosed an impending failure.
4. What is Spare Criticality
Assessment
Spare Critically Assessment plays an
important role in achieving the desired plant
availability at an optimum cost
Downtime for such plant and machinery is
prohibitively expensive
It has been observed in many industries that
the non-availability of spare parts, as and
when required for repairs, contributes to as
much as 50% of the total down time
5. Classification of Spare Parts
1. Critical spares
without which the machine can’t be operated even in
suboptimal efficiency
with a high failure rate
with long procurement lead time
without a substitute
used in critical machines (identified for preventive
maintenance)
2. Non critical spares
without which machine can run (at least sub optimally)
that have high reliability
that can be made / purchased in short notice
that have substitutes
available off shelf as standard parts (bearings etc.)
6. Models for Type of Spares
Non-repairable Spares
Partswhich fail can’t be repaired and must be
replaced with a new parts
7. Models for Type of Spares
Repairable Spares
Parts
which fail can be repaired and be used back
as spares
8. Assessment Method
Analytic hierarchy process
findout relevant factors of the critical spare parts
and determine the relative importance
Grey prediction model
find a sequence of each element corresponding
to future dynamism, thereby developing prediction
model
Back-propagation network
used as a tool for judging the predictability
Moving average method
The moving average (MA) is the mean of the
previous data sets used to perform CSP demand
10. Management of Spare Parts
Proper planning and control of spare parts
inventory.
Eg: Material forecast planning, Asset
recovery services, Equipment receiving and
staging, Equipment tracking and reporting.
11. How To Manage Spare Parts
1. Identify requirement
Standard procedures and relevant
documentation is obtained
Current holdings are monitored and checked
against levels determined by procedures
Each holding location is checked as to needs
12. How To Manage Spare Parts
2. Procure parts
Current holdings are matched with need
Requests for additional parts are made in
accordance with enterprise procedures
Checks are made as to extra holdings in other
locations
13. How To Manage Spare Parts
3. Initiate replacement process
Need for spare parts is determined
Data base is activated to check possible location of
specific parts required
Arrangements are put in place to deploy the part to
the site where it is required
Part is changed over with the faulty part
Faulty part is recovered and disposed of or returned
for repair as determined by condition and enterprise
policy
14. How To Manage Spare Parts
4. Reorder part replacements
Relevant part request (forms/documentation) is
completed and forwarded to the vendor
Delivery of replacement is followed up on a
regular and ongoing basis (eg: phone call)
Alternate spares are sought where difficulties
(delay/no stock) are experienced with
replacement
15. How To Manage Spare Parts
5. Complete administrative tasks
Relevant documentation is completed, signed
and forwarded to the appropriate area (eg:
Account Payable - Boucher, Account Receivable
– receiving documentation, Filing and Retention
document – filing history)
Regular audit of stock holdings is conducted in
accordance with enterprise policy
Checks are made to ensure that all parts are
latest issue and are compatible with installed
systems and equipment
16. Inventory
Inventory is the total amount of goods and/or
materials contained in a store or factory at any
given time.
Helps us know the precise number of items on
the shelves and storage areas in order to
place orders or control losses
18. Inventory Analysis
FSN Analysis
Fast Moving (F) = Items that are frequently issued say
more than once a month.
Slow Moving (S) = Items that are issued less than
once a month
Non-Moving (N) = Items that are not issuedused for
more than 2 years.
Help establishing most suitable stores layout by
locating all the fast moving items near the
dispensing window to reduce the handling efforts
19. Inventory Analysis
HML Analysis
HighCost (H) : Item whose unit value is very high
Medium Cost (M) : Item whose unit value is of
medium value
Low Cost (L) : Item whose unit value is low
Efforts may be necessary to find out the
means for prolonging the life of high value
parts through reconditioning and repair
20. Inventory Analysis
VED Analysis
VITAL (V) : A spare part will be termed vital, if on account of its
non-availability there will be very high loss due to production
downtime and/or a very high cost will be involved if the part is
procured on emergency basis. In a process industry, most spare
parts for the bottleneck machine or process will be of vital
nature.For example, bearings for a kiln in a cement plant will be
considered vital.
ESSENTIAL (E) : A spare part will be considered essential if, due
to its non-availability, moderate loss is incurred. For example,
bearings for motors of auxiliary pumps will be classified as
essential.
DESIRABLE (D) : A spare part will be desirable if the production
loss is not very significant due to its non-availability. Most of the
parts will fall under this category. For example, gaskets for piping
connection.