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Aligning classification and inventory control of spare parts
                      in the frame of an integrated management process

                                 Marco Macchi*, Irene Roda*, Luca Fumagalli*, Flavio
                                             Beretta**, Sammy Saba**

                      * Department of Management, Economics and Industrial Engineering, Politecnico di Milano,
                                       Piazza Leonardo Da Vinci 32, 20133 Milano, Italy,
                       ** ABB Spa Process Automation Division, Via Vittor Pisani 16, 20124 Milano, Italy
                          (email: marco.macchi@polimi.it; irene.roda@polimi.it; luca1.fumagalli@polimi.it;
                                        flavio.beretta@it.abb.com; sammy.saba@it.abb.com)

       Abstract: Spare parts management is an issue of outmost importance for effectiveness in manufacturing and
       service companies because of its impact on system availability and continuity of operations. On the other
       hand, spare parts are inherently difficult to manage in an efficient way. The present paper postulates that an
       integrated perspective for decision making in spare parts management provides potentials for positive results
       in both effectiveness and efficiency: a model for aligning classification and inventory control of spare parts is
       presented as a lever to this end.

       Keywords: Spare parts, integrated management process, classification, inventory control.

                                                                      hardly present in literature. Nonetheless, they think that
1. Introduction
                                                                      the adoption of an integrated perspective is one of the
Effective management of spare parts is essential to many              main lever for improving the overall performance (in
organizations since they represent an important resource              terms of effectiveness and efficiency) of spare parts
to ensure system availability and continuity of operations.           management in companies. This paper shares a similar
But spare parts are inherently difficult to manage in an              mindset, therefore it aims at contributing to fulfill the
efficient way: their inventories may consume a significant            needs for an integrated spare parts management. A main
portion of the capital investment in a company. Hence, in             assumption to this end is that a close attention should be
many organizations in the manufacturing, services and                 provided on the distinct characteristics pertaining to the
defense sectors, there are opportunities for cost savings by          spare parts, different from other types of materials.
engaging in more efficient management of spare parts
                                                                      The general function of spare parts is in fact to assist the
inventories (Diaz and Fu, 1997). Indeed, the objective of a
                                                                      maintenance staff in keeping equipment in an operating
company should be to achieve effectiveness, without
                                                                      condition. This means that the policies that govern the
losing efficiency. How to deal with such an objective?
                                                                      spare parts dynamics are different from those that govern
The advent of ERP (Enterprise Resource Planning)                      other types of materials such as the raw material, work-in-
system, and more specifically of CMMS (Computerized                   process and finished goods from a manufacturing plant.
Maintenance Management System), has favorably                         Spare parts are often characterized by stochastic demand
contributed to spare parts management, by supporting the              with irregular patterns; further on, it is normally observed
creation, archive and share of structured information on              that the rates of consumption for some parts are very high
MROs (Maintenance, Repair and Operations) items                       and for some others are very low; some parts are
(Labib, 1998). On the other hand, the knowledge behind                characterized by low purchasing costs, while many others
their proper usage is still retained in the human mind. In            have high or very high purchasing costs; last but not least,
fact, managing spare parts is not just a technical problem            procurement lead times are differentiated and they may be
which can be resolved by installing a specific ICT tool. It           high, especially in the case of specific or on order parts. A
rather requires an ‘engineering’ way of managing                      better insight on peculiarities characterizing the spare
maintenance processes and of integrating the several                  parts can be found in several studies in the scientific
activities involved: this motivates the need for systemic             literature such as, for example, Kennedy et al. (2001) and
actions, to support an integrated perspective for decision            Cavalieri et al. (2008).
making in spare parts management (Cavalieri et al., 2008).
                                                                      The core objective of this paper is the definition of a
Nonetheless, as stated by Bacchetti and Saccani (2011), a
                                                                      model which allows aligning the spare parts characteristics
major problem talking about spare parts stands in the
                                                                      – analysed thanks to a spare parts classification – with the
paucity of research with such a systemic perspective.
                                                                      subsequent selection of the inventory control model. The
These authors argue that an approach integrating spare
                                                                      alignment can be envisioned as a requirement for making
parts classification, demand management and forecasting,
                                                                      an integrated spare parts management system. The paper
inventory management and performance measurement is
                                                                      presents a proposal to this regard. Section 2 firstly defines
the integrated management process of spare parts and its           Spares’ demand forecasting is then an important phase –
objectives, it then focuses on the importance of aligning          phase 2 of the process – to proceed with the next phases.
classification and inventory control of spare parts. An            Special techniques are generally required for MROs since
analysis of the state of the art is undertaken in Section 3        a large portion of them are characterized by either
by focusing both on the existing classification methods            intermittent or lumpy demand. The outcome of this phase
and on the inventory control models abundantly discussed           is the achievement of demand information (demand size
in literature. Section 4 presents the model proposed in            and pattern), a relevant input for inventory control.
order to support the alignment: the model is developed
                                                                   Thereafter, the inventory analyses, carried out on the basis
and then clarified by a short example. Section 5 finally
                                                                   of different peculiar characteristics of the spare parts, such
discusses an agenda for future researches fulfilling the
                                                                   as annual consumption value, procurement lead time, unit
gaps still existent in this proposal.
                                                                   cost and frequency of use, help a company in establishing
2. Problem statement                                               suitable policies for selective control – step 1 of phase 3 –.
                                                                   This also helps in focusing further efforts on the operative
2.1 Integrated spare parts management process
                                                                   layer, to design the suited inventory control model – step
An integrated management process can be defined as an              2 of phase 3 –, thus systemizing the ordering procedure
approach that considers the different phases involved in           and also achieving, as a managerial goal, an optimum level
the process in order to get a holistic vision of the whole         of the inventory, with adequate balance of the trade-offs
stream of activities, with the objective of controlling them       in the target set of performances.
globally for granting the achievement of the desired final
                                                                   The application of computer-based applications (e.g., a
results. This is quite a general definition. Accordingly, the
                                                                   CMMS) for processing spare parts information and for
management process of spare parts can be organized as an
                                                                   operating spare parts control system is then needed for
integrated stream of activities leading to the management
                                                                   the organization and ensures timely operational actions
decisions (e.g. how many spares to keep in stock, how
                                                                   for an efficient and effective spare parts management –
many and when to re-order, etc…), with the objective of
                                                                   phase 4 of the process –.
granting the achievement of a target set of performances.
The integrated process, as given in Figure 1, is derived           Last but not least, policy test and validation is intended as
from Cavalieri et al. (2008) and consists of five phases.          the last phase – phase 5 of the process –. This should help
                                                                   orienteering toward a continuous improvement approach:
                                                                   each selected policy should be tested, reviewed and, if not
                                                                   valid, modified, going back to previous decision making
                                                                   phases.
                                                                   2.3 On the alignment between classification and inventory control
                                                                   As it emerges from the previous section, spare parts
                                                                   classification and demand forecasting can (and should) be
   Figure 1. Integrated spare parts management process             related to inventory control (Boylan, Syntetos, 2008).

Figure 1 envisions a continuous improvement approach,              This work focuses on the potentialities for improvements
starting from phase 1 to 5 and back, as well as a number           which may be reached not only through a dedicated
of sub-steps required along the process in some phases.            inventory control policy implementation, but thanks to a
                                                                   better alignment between the spare parts classification and
According to the best practices cited in literature, the           the selection of the most adequate inventory control
management decisions in all the phases should be made              model. The basic assumption is that the spare parts
having in mind a systemic perspective, and adopting a              classification has to respond to the need of considering
differentiated approach, where different kinds of spare            the spare parts characteristics in order to define the
parts are treated with different demand and inventory              criticality of each item / class of items. This phase allows
management techniques (Boylan, Syntetos, 2008).                    to consequentially define which is the best inventory
2.2 Objectives of each phase of the integrated process             control model to be used in order to manage the specific
                                                                   item / class of items. The idea is then to create a
Part codification and classification – steps of phase 1 of         mechanism that helps mapping the spares’ characteristics
the integrated process – help the organization minimizing          with the most proper inventory model applicable for their
the duplication of spare parts stocking thereby reducing           management. As far as the demand forecasting phase
inventories, aid the accounting process and facilitate the         regards, this work does not consider this specific aspect.
computerization of spare parts inventory control systems           To those interested, Syntetos and Keyes (2009) carried out
and, most of all, allow identifying different classes of spare     a recent review of spare parts forecasting literature.
parts basing on their peculiar characteristics. In particular,
the identification of peculiarities is an important task since     3. State of the Art
it enables to differentiate the spare items, with the goal to      3.1. Classification of spare parts
characterize the so called ‘criticality’: this is a leading well
discussed concept in spare parts management to drive               Criticality of spare parts is probably the first feature that is
subsequent decisions and, in fact, the inventory control           pronounced by the spare part logistics practitioners while
may be decided driven by it.                                       enquired about specific item characteristics (Huiskonen,
2001) and the classification step aims at categorizing the                            literature to this end are often too complicated and limited
spare parts basing on it. Since both quantitative and                                 due to computational efforts (e.g. the use of a linear
qualitative factors (e.g., price, lead time, specificity, stock                       optimization model): limits have to be considered when
out costs, severity, etc.) may be considered as criteria for                          implementing the method in industry. Among the several
assessing criticality, the methodology to be followed for                             methods from literature, the AHP is proposed in this
implementing such a phase deserves special attention.                                 work as a proper method for spare parts classification
                                                                                      and, looking ahead along the integrated management
If the traditional methods for classification were based on
                                                                                      process, for aiding the alignment of classification and
single classification criterion (see traditional quantitative
                                                                                      inventory control. AHP is one of the most quoted MCIC
ABC-Pareto analysis) or on pure qualitative considerations
                                                                                      method when referring to spare parts, since many years:
(see VED analysis, categorizing spares into Vital, Essential
                                                                                      Gajpal and Ganesh, 1994 is one of the first example of
or Desirable items), more recently there has been a trend
                                                                                      use of AHP for spare parts classification, to characterize
showing that researchers started to assess the necessity of
                                                                                      their criticality. A part from its consolidated use, two
considering more than one criterion and both quantitative
                                                                                      aspects were taken into account to further motivate its
and qualitative factors. Indeed, the discussion in literature
                                                                                      selection: (i) the simplicity, in terms of computational
is bringing to the actual remark that a well-structured
                                                                                      applicability of the method; (ii) the adaptability to the
classification of spare parts cannot be based neither just
                                                                                      needs to assess criticality, by taking into account several
on one single criterion nor on qualitative judgments only.
                                                                                      factors, both quantitative and qualitative ones.
The need for a multi-criteria inventory classification
(MCIC) started to be disclosed in the research literature.                            Briefly, the AHP consists in a decision-support procedure
In fact, only a proper multi-criteria classification can lead                         for dealing with complex, unstructured, and multiple-
to the definition of critical spare items which reflects the                          attribute decisions. It is a powerful tool to find out the
real priorities, given to different criteria. A selection of                          relative priorities or weights to be assigned to different
meaningful research works about MCIC classification                                   criteria which characterize a decision (Saaty, 1990).
methods is proposed in Table 1. The table summarizes an                               Focusing on the scope of classifying spare parts basing on
in-depth analysis of literature done as a preparation of this                         several criticality criteria, three basic steps are needed for
paper. The reader may consider, for details on different                              using AHP.
classification methods, the study by Molenaers et all.
                                                                                      (1) The description of the decision problem with a hierarchical
(2011) as a general review.
                                                                                      structure. Within this context the problem’s structure can
  MODEL                  ADVANTAGES                   DRAWBACKS                       be presented as it is in Figure 2. The main element is the
  Bi-criteria            It introduces more than      It is considered too
  approach               one criterion, hence it      much demanding if
                                                                                      final objective of the problem, at the top level of the
                         enlarges the capability      more than two criteria          hierarchy, which is the calculation of an overall criticality
                         of traditional methods       are adopted (this is due        index for each spare item. The criteria to be considered
                         (e.g. by a joint ABC +       to high computational
                         VED analysis)                complexity)                     for calculating the criticality index itself are defined at the
  AHP-Analytic           It is a multi-criteria       It requires judgments to        middle level and finally the modes, which each criterion
  Hierarchy Process      decision supporting a        be expressed by an
                         method for calculating       expert (i.e. subjective         can assume depending on its value (high, medium, low),
                         an overall criticality       judgments)                      are set by the definition of proper ranges (for the values).
                         index

  ABC-fuzzy              It allows considering        A practical applicability
  classification          nominal and non-             is difficult (this is due to
                         nominal attributes           high        computational
                                                      complexity)
  DEA (Data              It computes the weights      It is considered too
  envelopment            for the criteria by an       much demanding if the
  Approach) –            optimization method;         number of spare parts
  Weighted Linear        this allows to overcome      to classify is high (due
  Optimization           problems       connected     to high computational
  method                 with            subjective   complexity)
                         judgments
  Single overall score   It is simple to use          When the number of
  of an inventory                                     criteria is large, it is not
  item –calculation                                   an easy task for a
  by skipping                                         decision maker to rank                Figure 2. Structure of the classification problem
  optimization                                        all the criteria as it is
                                                      required.                       (2) The use of pair-wise comparisons is carried on to estimate: i)
                                                      It is only applicable for
                                                      continuous           criteria   the relative weights (reflecting the given importance) of
                                                      measures                        each criterion comparing to the others and ii) the relative
                                                                                      importance of the modes, given each criterion, with
   Table 1. MCIC methods: advantages and drawbacks
                                                                                      respect to the overall criticality (e.g. the higher the price of
It is important to underline that a common issue of spare                             the item is, the higher its overall criticality will be).
parts classification with a multi-criteria perspective is the
                                                                                      (3) The integration of weights in order to obtain an overall
identification of the relative importance of criteria: hence,                         importance (weight) for each criterion reflects its contribute over
the MCIC methods comprise either algorithms, models,
                                                                                      the overall criticality definition of an item, both in term of
approaches or also rules of thumb for deciding the relative                           relative importance with respect to the other criteria and
weights (measuring the relative importance) of the criteria
                                                                                      of its mode implications.
defining the overall criticality. The proposals from
(4) The calculation of the overall criticality index as the sum of     criticality index, as previously described. In this way, not
the criteria’s weights obtained in the previous step.                  only a proper classification based on the overall criticality
                                                                       index can be implemented, but also a useful input for the
The use of AHP in order to classify spare parts and to aid
                                                                       next step of inventory control is available: that is what we
the alignment of classification and inventory control is
                                                                       call the ‘criticality profile’ of the spare item / class of
presented further in this paper.
                                                                       items which, according to the AHP procedure, simply
3.2 Inventory control models                                           results from the hierarchy reflecting the problem under
                                                                       analysis and, in particular, it is the decomposition of the
When one considers inventory control models, he/she                    overall criticality index into its component criteria taking
naturally associates them to the stock sizing problem. An              into account their overall weights which comprehend
inventory model has in fact a clear impact on the stock                both the importance and mode’s implications. In the radar
level reached during plant operation. The general scope of             chart of Figure 3, the criticality profile of an item is
stock sizing is: ‘to find the smallest integer number of               represented, where Ci are the decision criteria.
spare parts which must be stocked, so that requirement                                                0,05
                                                                                                             C1


for parts from the installed base, during a cumulative                                                0,04

operating time T, is met with a given probability R’                                                  0,03


(Birolini, 2004). To this end, different alternatives of
                                                                                                      0,02
                                                                                            C5                         C2
                                                                                                      0,01

inventory control model can be decided.                                                               0,00



An inventory model is usually characterized according to
two main parameters, used for controlling the stock level
(Cavalieri, 2008): (i) a criterion (x) that specifies the
                                                                                                 C4               C3



conditions under which a new order of spare parts should                   Figure 3. Example of a criticality profile of an item
be issued; (ii) a reference point (y) for the quantity to be
                                                                       As far as the criteria to be considered, given an in-depth
ordered. Inventory models can be classified with the
                                                                       taken analysis from both literature and industrial survey
couple (x, y), where both x and y can assume different
                                                                       (Roda, 2012), five criteria have been selected as the most
values depending upon the type of inventory review (i.e.
                                                                       proper ones for MROs classification: Lead Time, Price,
periodic or continuous review) and the optimal order size.
                                                                       Turnover Rate, Stock out cost and Specificity.
Literature is full of proposed inventory control models
                                                                       After the implementation of the AHP methodology, the
but each of them seems to be presented, in most of the
                                                                       spare items are then classified with respect to an overall
cases, without an explicit connection with the peculiarities
                                                                       index, which takes into account more than one criteria,
of the spare parts for which it is recommended to be
                                                                       and the items’ criticality profiles are also available. It is
applied to. No or few works in fact speak about the
                                                                       now possible to carry on with the next step dealing with
applicability of the inventory control models they present,
                                                                       the selection of inventory control models: the idea is to
referring to spare parts different characteristics. For this
                                                                       assign the proper control model to criticality profiles; to
work concern, 4 inventory control models are considered
                                                                       this end, the applicability conditions for each control
and studied in their applicability: (i) the continuous review,
                                                                       model are analysed, in order to fit the inventory models
with fixed reorder point (r) and fixed order quantity (Q),
                                                                       features with the criticality profiles.
referred to as (Q, r); (ii) the continuous review, with fixed
re-order point (s) and order-up-to level (S), referred to as           4.2 Applicability of inventory control models
(s, S); (iii) the periodic review, with fixed ordering interval
(T) and order-up-to level (R), referred to as (T,R); (iv) the          The idea at the basis of this paper is to find proper models
continuous review and order-up-to level (S) in a one-for-              to manage stocking and purchasing of maintenance items,
one replenishment mode, referred to as (S-1, S).                       considering that within a stock there are several different
                                                                       classes of spares, each one with their own peculiarities. In
Specifics about the algorithms on which the models base                particular, by referring to the categorization of the actual
on are not presented in this paper: plenty of literature               stock of a company, resulting from the classification step,
works can be found about this issue. On the other hand, a              this step now aims at the selection of the best model to
discussion is herein presented for what concern their                  manage each class of spares / each critical spare item. A
applicability: this aims at providing a better focus on the            framework is required to this end which, acting as a meta-
alignment of the outcomes of spare part classification and             model, allows to relate different inventory control models
the selection of inventory control.                                    to different characteristics of the spare parts.
                                                                       The framework considers, according to the proposal of
4. Model Definition
                                                                       this paper, the ‘criticality profiles’ of the classes of spares
                                                                       /spares as to drive the selection. Hence, an analysis of
4.1. Using AHP in spare parts classification as a tool for alignment   applicability conditions of each inventory model has been
As far as the classification step concerns, the objective is           undertaken to build the framework, driven by the
the definition of a criticality index for each spare item /            elements measured in the ‘criticality profiles’. In particular,
class of items. Once the criteria to be considered in the              the aim has been to identify the peculiarities of the items
decision process have been defined, by using the AHP it is             to which an inventory model best fits, based on the theory
easy to determine the weight that each of them has on the              already presented in literature references plus additional
final assessment of criticality and to calculate the overall           considerations logically derived by a deductive process
initiated from the inventory control models’ properties         and can be easily found in the market (i.e., mid to low
themselves.                                                     specificity).
For what concern the (Q, r) models, it is widely stated and     4.3 Model development
approved in literature that they are implementing policies
                                                                By structuring the reasoning presented in the previous
for fast or normal moving spare items: Gelders and Loony
                                                                subsection it is possible to finally define the framework:
(1978), for example, empirically demonstrate the classical
                                                                this is materialized as a matrix able to guide the decision
EOQ model as appropriate for normal and fast moving
                                                                about which inventory control model to be used for a
items; Porras and Dekker (2008) also present the (Q,r)
                                                                particular item’s criticality profile, by referring to the
model with normal approximation of the demand as a
                                                                mode assumed by each criterion for that item (Table 2).
suitable model for items with high turnover rate. As far as
the lead time concerns, these models are usually applied in                        C1                   C2               C3                C4                    C5
                                                                                  Lead                 Price          Turnover         Stock Out              Specificity
case of long lead times (Fera, Lambiase, 2010). Since they                        Time                                  Rate              Cost
are based on the continuous review, these models enable           (Q,r)       Mid/long                 High           Mid/high             Mid/low             Mid/low
to keep the average stock level lower than in the periodic        (s,S)           Short                High             Low                Mid/high            Mid/high
review: they are then preferable for high price spare items,
                                                                 (T,R)       Mid/short                 Low            Mid/low                Low               Mid/low
because of the resulting lower holding costs. Thereafter, in
practice, the (Q,r) models are normally mentioned for            (S-1,S)          Long                 High             Low                  Mid               Mid/high

managing either consumables or generic materials (that is,
materials characterized by low or, at most, mid specificity).       Table 2. The framework to select inventory control
Further on, no particular concern is given to the stock out          models starting from the classification outcomes
costs: it can be deduced that low/mid stock out costs can
be considered as the applicable characteristics.                The selection will be guided by the criticality profile which
                                                                identifies the most critical criteria for a certain item and
The (s, S) model is based on the assumption that demand         which are the ones to be considered first in the selection
behaves as a Poisson distribution; the (S-1, S) model is a      of the model. The following steps may be considered: (1)
particular case of (s,S) model, with an underlying Poisson      consider the criterion with the highest value in the
demand distribution as well (Feeney and Sherbrooke,             criticality profile composition; (2.) look at its mode (high,
1966). These models are globally proven in literature as        medium or low); (3.) by using the framework, select the
the best choice for slow moving items. Moreover, the            models which can be used for such criterion’s mode
models are usually preferred for spares with high price. In     (scroll the criterion column and select the rows where the
particular, (S-1, S) model is the most appropriate when         value in the cells corresponds to the mode assumed by the
demands and order costs are relatively low, and the spares’     criterion); if the models (rows) selected are more than 1,
prices are high (Rose, 1972), especially when the lead time     go to step 1, else stop.
is long. On the other hand, the continuous review of the
(s, S) model fits well with items characterized by a short      4.4 An example
lead time (Duchessi et al., 1988). In practice, these models
                                                                A short example in order to clarify the usage of the model
are usually mentioned for stocking specific materials (that
                                                                developed in the paper is herein given. After using AHP
is, materials with a mid/high specificity) and in case of
                                                                for classifying the components of the combustion system
mid/high stock out costs (this is mentioned especially for
                                                                of a mining truck’s engine, the overall criticality index
the case of (s,S)).
                                                                obtained for each of them allows to identify the most
The (T,R) model is run in the common use particularly in        critical one, that is the fuel tank. The radar chart in Figure
companies not utilizing computerized control. This is also      4 shows the criticality profile of that item.
frequently seen when the spare items are ordered from the
                                                                                                               C1: LEAD TIME
                                                                                                                0,4

same supplier, or require resource sharing. Because of the                                                      0,3


periodic review, this model leads to higher stocks, then                                                        0,2
                                                                                     C5: SPECIFICITY                                        C2: PRICE
higher holding costs, than the continuous review: this is a                                                     0,1


reason why the (T,R) model can be better justified for low                                                      0,0


price items. With higher stocks, mid to low turnover rates
are expected for the model: this depends on the demand
rate, not high with maintenance materials. Differently to                                     C4: STOCK OUT
                                                                                                   COST
                                                                                                                                  C3: TR


the ones above, in this case the order quantity is not fixed
                                                                              Figure 4. Fuel Tank’s criticality profile
but the inventory level is restored to its maximum value
each replenishment period: this approach is simple and
usually applied for not very critical parts in term of stock    From the criticality profile (see Figure 4) and the criteria
out costs. In practice, the periodic review can be justified    modes assumed by the item (see Table 3), it is then
also for what concern the lead time: with mid/short lead        possible to select the inventory control model, by using
time, the periodic review is acceptable, while not being        the framework (of Table 2).
forced to implement a computerized control to keep                          C1              C2               C3                    C4                      C5
stocks under a continuous review. This is often                            Lead            Price          Turnover             Stock Out                Specificity
                                                                           Time                             Rate                  Cost
accompanied by the fact that materials are quite generic                   Long            High             Low                   High                  Mid/High
                                                                                  Table 3. Fuel Tank’s criteria modes
Starting from the criterion with the highest weight in the      capacity, European Journal of Operational Research, 97: 480-
overall criticality index (i.e. the lead time) and following    492.
the algorithm presented in the previous section, the (S-
                                                                Duchessi P., Tayi G. K., Levy J. B, A (1988) ;Conceptual
1,S) model is selected as the most proper one.
                                                                Approach for Managing of Spare Parts, International Journal
5. Conclusions                                                  of Physical Distribution & Logistics Management, Vol. 18 Iss: 5,
                                                                pp.8 – 15
The major problem, for the framework developed in this
paper to be more consistent and solid, stands in the            Feeney G. J., Sherbrooke C. (1966), The (S-1,S) Inventory
paucity of research with an integrated perspective on spare     Policy under Compound Poisson Demand, Management
parts management: as evidenced from literature review, an       Science, Vol. 12, No. 5, A ,Sciences, 391-411
approach integrating spare parts classification, demand
                                                                Fera, Lambiase Nenni (2010), A Proposal for Estimating
forecasting, inventory control models and performance
                                                                the Order Level for Slow Moving Spare Parts Subject to
measurement is hardly present in literature. In order to fill
                                                                Obsolescence, iBusiness, 2, 232-237
this gap, in this work a deductive process has been used
with the aim of handling the few information from               Gajpal P. P., Ganesh L. S. (1994), Criticality analysis of
literature about differentiated ways of managing spare          spare parts using the analytic hierarchy process,
parts in the most consistent way in order to obtain the         International Journal of Production Economics, Vol. 35, Iss 1-
framework. Of course, this methodology is useful to             3,pp 293-297
create the basis for the definition of a model; building of
more theory is necessary to define a complete and robust        Gelders L.F., Van Looy P.M. (1978), An Inventory Policy
framework. In particular, detailed and focused empirical        for Slow and Fast Movers in a Petrochemical Plant: A
investigations are required in the next future for validation   Case Study, The Journal of the Operational Research Society,
of the framework: case studies and proper testing, such as      Vol. 29, No. 9, pp. 867-874
with simulation, to verify the adaptation to a real setting     Huiskonen (2001), Maintenance spare parts logistics:
of the framework, will be required. This will help studying     Special characteristics and strategic choices, International
different scenarios and validating models, considering also     Journal of Production Economics, Vol71, Iss1-3, 6, pp125-133
the dynamics in the application in a real industrial world.
                                                                Kennedy, WJ, Patterson, JW, Fredendall, LD. (2002) , An
Acknowledgments                                                 overview of recent literature on spare parts inventories,
                                                                International Journal of Production Economics, 76(2): 201–215.
This paper grounds on a research supported with the
project “Dote Ricerca applicata: MeS-MaM - Metodi e             Labib A.W., (1998) World-class maintenance using a
Strumenti per la riduzione dei costi di gestione dei            computerised maintenance management system, Journal of
Materiali di Manutenzione” (in English: Methods and             Quality in Maintenance Engineering, Vol. 4 Iss: 1, pp.66 - 75
tools for the reduction of cost of spare parts). The project    Molenaers A., Baets H., Pintelon L., Waeyenbergh
was funded by Regione Lombardia (Lombardy Region)               G.(2011), Criticality classification of spare parts: A case
and ABB Spa Process Automation Division. The authors            study, International Journal of Production Economics (to be
would like to thank the other persons that contributed to       published).
the project, namely Eng. Federico Curcio formerly M.Sc
student from Politecnico di Milano and Eng. Salvatore De        Porras, Dekker (2008), An inventory control system for
Angelis project manager from ABB Spa Process                    spare parts at a refinery: An empirical comparison of
Automation Division.                                            different re-order point methods, European Journal of
                                                                Operational Research 184 pp.101–132
References                                                      Roda I. (2012), An integrated decision framework for
Bacchetti A., Saccani N. (2011), Spare parts classification     Spare parts classification and Inventory control policy
and demand forecasting for stock control: Investigating         selection: Conceptualization, development and validation
the gap between research and practice, Omega, Vol40, Iss6,      in industrial contexts; MSc Thesis (Politecnico di Milano)
722-737                                                         Rose M. (1972), The (S-1, S) Inventory Model with
Birolini (2004), Reliability engineering: theory and            Arbitrary Back-Ordered Demand and Constant Delivery
practice, 4th, Berlin: Springer                                 Times, Operations Research, Vol. 20, No. 5, pp. 1020-1032

Boylan, J.E., Syntetos A.A. and Karakostas G.C. (2008),         Saaty T. L. (1990), How To Make A Decision: The
Classification for forecasting and stock control: a case        Analytic Hierarchy Process, European Journal of Operational
study, Journal of the Operational Research Society, 59, 4       Research 48 9-26

Cavalieri S., Garetti M., Macchi M., Pinto R. (2008), A         Syntetos, A., Keyes, M. & Babai, M. (2009), Demand
decision-making framework for managing maintenance              categorization in a European spare parts logistics network,
spare part, Production Planning & Control , Vol. 19, Iss. 4.    International Journal of Operations & Production Management,
                                                                29(3-4), 292-316
Díaz, A., Fu, M.C. (1997), Models for multi-echelon
repairable item inventory systems with limited repair           Wagner S.M., Lindemann E., A case study-based analysis
                                                                of spare parts management in the engineering industry,
                                                                Production Planning & Control, Vol. 19, Iss. 4

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Spare parts final 27072012 - paper

  • 1. Aligning classification and inventory control of spare parts in the frame of an integrated management process Marco Macchi*, Irene Roda*, Luca Fumagalli*, Flavio Beretta**, Sammy Saba** * Department of Management, Economics and Industrial Engineering, Politecnico di Milano, Piazza Leonardo Da Vinci 32, 20133 Milano, Italy, ** ABB Spa Process Automation Division, Via Vittor Pisani 16, 20124 Milano, Italy (email: marco.macchi@polimi.it; irene.roda@polimi.it; luca1.fumagalli@polimi.it; flavio.beretta@it.abb.com; sammy.saba@it.abb.com) Abstract: Spare parts management is an issue of outmost importance for effectiveness in manufacturing and service companies because of its impact on system availability and continuity of operations. On the other hand, spare parts are inherently difficult to manage in an efficient way. The present paper postulates that an integrated perspective for decision making in spare parts management provides potentials for positive results in both effectiveness and efficiency: a model for aligning classification and inventory control of spare parts is presented as a lever to this end. Keywords: Spare parts, integrated management process, classification, inventory control. hardly present in literature. Nonetheless, they think that 1. Introduction the adoption of an integrated perspective is one of the Effective management of spare parts is essential to many main lever for improving the overall performance (in organizations since they represent an important resource terms of effectiveness and efficiency) of spare parts to ensure system availability and continuity of operations. management in companies. This paper shares a similar But spare parts are inherently difficult to manage in an mindset, therefore it aims at contributing to fulfill the efficient way: their inventories may consume a significant needs for an integrated spare parts management. A main portion of the capital investment in a company. Hence, in assumption to this end is that a close attention should be many organizations in the manufacturing, services and provided on the distinct characteristics pertaining to the defense sectors, there are opportunities for cost savings by spare parts, different from other types of materials. engaging in more efficient management of spare parts The general function of spare parts is in fact to assist the inventories (Diaz and Fu, 1997). Indeed, the objective of a maintenance staff in keeping equipment in an operating company should be to achieve effectiveness, without condition. This means that the policies that govern the losing efficiency. How to deal with such an objective? spare parts dynamics are different from those that govern The advent of ERP (Enterprise Resource Planning) other types of materials such as the raw material, work-in- system, and more specifically of CMMS (Computerized process and finished goods from a manufacturing plant. Maintenance Management System), has favorably Spare parts are often characterized by stochastic demand contributed to spare parts management, by supporting the with irregular patterns; further on, it is normally observed creation, archive and share of structured information on that the rates of consumption for some parts are very high MROs (Maintenance, Repair and Operations) items and for some others are very low; some parts are (Labib, 1998). On the other hand, the knowledge behind characterized by low purchasing costs, while many others their proper usage is still retained in the human mind. In have high or very high purchasing costs; last but not least, fact, managing spare parts is not just a technical problem procurement lead times are differentiated and they may be which can be resolved by installing a specific ICT tool. It high, especially in the case of specific or on order parts. A rather requires an ‘engineering’ way of managing better insight on peculiarities characterizing the spare maintenance processes and of integrating the several parts can be found in several studies in the scientific activities involved: this motivates the need for systemic literature such as, for example, Kennedy et al. (2001) and actions, to support an integrated perspective for decision Cavalieri et al. (2008). making in spare parts management (Cavalieri et al., 2008). The core objective of this paper is the definition of a Nonetheless, as stated by Bacchetti and Saccani (2011), a model which allows aligning the spare parts characteristics major problem talking about spare parts stands in the – analysed thanks to a spare parts classification – with the paucity of research with such a systemic perspective. subsequent selection of the inventory control model. The These authors argue that an approach integrating spare alignment can be envisioned as a requirement for making parts classification, demand management and forecasting, an integrated spare parts management system. The paper inventory management and performance measurement is presents a proposal to this regard. Section 2 firstly defines
  • 2. the integrated management process of spare parts and its Spares’ demand forecasting is then an important phase – objectives, it then focuses on the importance of aligning phase 2 of the process – to proceed with the next phases. classification and inventory control of spare parts. An Special techniques are generally required for MROs since analysis of the state of the art is undertaken in Section 3 a large portion of them are characterized by either by focusing both on the existing classification methods intermittent or lumpy demand. The outcome of this phase and on the inventory control models abundantly discussed is the achievement of demand information (demand size in literature. Section 4 presents the model proposed in and pattern), a relevant input for inventory control. order to support the alignment: the model is developed Thereafter, the inventory analyses, carried out on the basis and then clarified by a short example. Section 5 finally of different peculiar characteristics of the spare parts, such discusses an agenda for future researches fulfilling the as annual consumption value, procurement lead time, unit gaps still existent in this proposal. cost and frequency of use, help a company in establishing 2. Problem statement suitable policies for selective control – step 1 of phase 3 –. This also helps in focusing further efforts on the operative 2.1 Integrated spare parts management process layer, to design the suited inventory control model – step An integrated management process can be defined as an 2 of phase 3 –, thus systemizing the ordering procedure approach that considers the different phases involved in and also achieving, as a managerial goal, an optimum level the process in order to get a holistic vision of the whole of the inventory, with adequate balance of the trade-offs stream of activities, with the objective of controlling them in the target set of performances. globally for granting the achievement of the desired final The application of computer-based applications (e.g., a results. This is quite a general definition. Accordingly, the CMMS) for processing spare parts information and for management process of spare parts can be organized as an operating spare parts control system is then needed for integrated stream of activities leading to the management the organization and ensures timely operational actions decisions (e.g. how many spares to keep in stock, how for an efficient and effective spare parts management – many and when to re-order, etc…), with the objective of phase 4 of the process –. granting the achievement of a target set of performances. The integrated process, as given in Figure 1, is derived Last but not least, policy test and validation is intended as from Cavalieri et al. (2008) and consists of five phases. the last phase – phase 5 of the process –. This should help orienteering toward a continuous improvement approach: each selected policy should be tested, reviewed and, if not valid, modified, going back to previous decision making phases. 2.3 On the alignment between classification and inventory control As it emerges from the previous section, spare parts classification and demand forecasting can (and should) be Figure 1. Integrated spare parts management process related to inventory control (Boylan, Syntetos, 2008). Figure 1 envisions a continuous improvement approach, This work focuses on the potentialities for improvements starting from phase 1 to 5 and back, as well as a number which may be reached not only through a dedicated of sub-steps required along the process in some phases. inventory control policy implementation, but thanks to a better alignment between the spare parts classification and According to the best practices cited in literature, the the selection of the most adequate inventory control management decisions in all the phases should be made model. The basic assumption is that the spare parts having in mind a systemic perspective, and adopting a classification has to respond to the need of considering differentiated approach, where different kinds of spare the spare parts characteristics in order to define the parts are treated with different demand and inventory criticality of each item / class of items. This phase allows management techniques (Boylan, Syntetos, 2008). to consequentially define which is the best inventory 2.2 Objectives of each phase of the integrated process control model to be used in order to manage the specific item / class of items. The idea is then to create a Part codification and classification – steps of phase 1 of mechanism that helps mapping the spares’ characteristics the integrated process – help the organization minimizing with the most proper inventory model applicable for their the duplication of spare parts stocking thereby reducing management. As far as the demand forecasting phase inventories, aid the accounting process and facilitate the regards, this work does not consider this specific aspect. computerization of spare parts inventory control systems To those interested, Syntetos and Keyes (2009) carried out and, most of all, allow identifying different classes of spare a recent review of spare parts forecasting literature. parts basing on their peculiar characteristics. In particular, the identification of peculiarities is an important task since 3. State of the Art it enables to differentiate the spare items, with the goal to 3.1. Classification of spare parts characterize the so called ‘criticality’: this is a leading well discussed concept in spare parts management to drive Criticality of spare parts is probably the first feature that is subsequent decisions and, in fact, the inventory control pronounced by the spare part logistics practitioners while may be decided driven by it. enquired about specific item characteristics (Huiskonen,
  • 3. 2001) and the classification step aims at categorizing the literature to this end are often too complicated and limited spare parts basing on it. Since both quantitative and due to computational efforts (e.g. the use of a linear qualitative factors (e.g., price, lead time, specificity, stock optimization model): limits have to be considered when out costs, severity, etc.) may be considered as criteria for implementing the method in industry. Among the several assessing criticality, the methodology to be followed for methods from literature, the AHP is proposed in this implementing such a phase deserves special attention. work as a proper method for spare parts classification and, looking ahead along the integrated management If the traditional methods for classification were based on process, for aiding the alignment of classification and single classification criterion (see traditional quantitative inventory control. AHP is one of the most quoted MCIC ABC-Pareto analysis) or on pure qualitative considerations method when referring to spare parts, since many years: (see VED analysis, categorizing spares into Vital, Essential Gajpal and Ganesh, 1994 is one of the first example of or Desirable items), more recently there has been a trend use of AHP for spare parts classification, to characterize showing that researchers started to assess the necessity of their criticality. A part from its consolidated use, two considering more than one criterion and both quantitative aspects were taken into account to further motivate its and qualitative factors. Indeed, the discussion in literature selection: (i) the simplicity, in terms of computational is bringing to the actual remark that a well-structured applicability of the method; (ii) the adaptability to the classification of spare parts cannot be based neither just needs to assess criticality, by taking into account several on one single criterion nor on qualitative judgments only. factors, both quantitative and qualitative ones. The need for a multi-criteria inventory classification (MCIC) started to be disclosed in the research literature. Briefly, the AHP consists in a decision-support procedure In fact, only a proper multi-criteria classification can lead for dealing with complex, unstructured, and multiple- to the definition of critical spare items which reflects the attribute decisions. It is a powerful tool to find out the real priorities, given to different criteria. A selection of relative priorities or weights to be assigned to different meaningful research works about MCIC classification criteria which characterize a decision (Saaty, 1990). methods is proposed in Table 1. The table summarizes an Focusing on the scope of classifying spare parts basing on in-depth analysis of literature done as a preparation of this several criticality criteria, three basic steps are needed for paper. The reader may consider, for details on different using AHP. classification methods, the study by Molenaers et all. (1) The description of the decision problem with a hierarchical (2011) as a general review. structure. Within this context the problem’s structure can MODEL ADVANTAGES DRAWBACKS be presented as it is in Figure 2. The main element is the Bi-criteria It introduces more than It is considered too approach one criterion, hence it much demanding if final objective of the problem, at the top level of the enlarges the capability more than two criteria hierarchy, which is the calculation of an overall criticality of traditional methods are adopted (this is due index for each spare item. The criteria to be considered (e.g. by a joint ABC + to high computational VED analysis) complexity) for calculating the criticality index itself are defined at the AHP-Analytic It is a multi-criteria It requires judgments to middle level and finally the modes, which each criterion Hierarchy Process decision supporting a be expressed by an method for calculating expert (i.e. subjective can assume depending on its value (high, medium, low), an overall criticality judgments) are set by the definition of proper ranges (for the values). index ABC-fuzzy It allows considering A practical applicability classification nominal and non- is difficult (this is due to nominal attributes high computational complexity) DEA (Data It computes the weights It is considered too envelopment for the criteria by an much demanding if the Approach) – optimization method; number of spare parts Weighted Linear this allows to overcome to classify is high (due Optimization problems connected to high computational method with subjective complexity) judgments Single overall score It is simple to use When the number of of an inventory criteria is large, it is not item –calculation an easy task for a by skipping decision maker to rank Figure 2. Structure of the classification problem optimization all the criteria as it is required. (2) The use of pair-wise comparisons is carried on to estimate: i) It is only applicable for continuous criteria the relative weights (reflecting the given importance) of measures each criterion comparing to the others and ii) the relative importance of the modes, given each criterion, with Table 1. MCIC methods: advantages and drawbacks respect to the overall criticality (e.g. the higher the price of It is important to underline that a common issue of spare the item is, the higher its overall criticality will be). parts classification with a multi-criteria perspective is the (3) The integration of weights in order to obtain an overall identification of the relative importance of criteria: hence, importance (weight) for each criterion reflects its contribute over the MCIC methods comprise either algorithms, models, the overall criticality definition of an item, both in term of approaches or also rules of thumb for deciding the relative relative importance with respect to the other criteria and weights (measuring the relative importance) of the criteria of its mode implications. defining the overall criticality. The proposals from
  • 4. (4) The calculation of the overall criticality index as the sum of criticality index, as previously described. In this way, not the criteria’s weights obtained in the previous step. only a proper classification based on the overall criticality index can be implemented, but also a useful input for the The use of AHP in order to classify spare parts and to aid next step of inventory control is available: that is what we the alignment of classification and inventory control is call the ‘criticality profile’ of the spare item / class of presented further in this paper. items which, according to the AHP procedure, simply 3.2 Inventory control models results from the hierarchy reflecting the problem under analysis and, in particular, it is the decomposition of the When one considers inventory control models, he/she overall criticality index into its component criteria taking naturally associates them to the stock sizing problem. An into account their overall weights which comprehend inventory model has in fact a clear impact on the stock both the importance and mode’s implications. In the radar level reached during plant operation. The general scope of chart of Figure 3, the criticality profile of an item is stock sizing is: ‘to find the smallest integer number of represented, where Ci are the decision criteria. spare parts which must be stocked, so that requirement 0,05 C1 for parts from the installed base, during a cumulative 0,04 operating time T, is met with a given probability R’ 0,03 (Birolini, 2004). To this end, different alternatives of 0,02 C5 C2 0,01 inventory control model can be decided. 0,00 An inventory model is usually characterized according to two main parameters, used for controlling the stock level (Cavalieri, 2008): (i) a criterion (x) that specifies the C4 C3 conditions under which a new order of spare parts should Figure 3. Example of a criticality profile of an item be issued; (ii) a reference point (y) for the quantity to be As far as the criteria to be considered, given an in-depth ordered. Inventory models can be classified with the taken analysis from both literature and industrial survey couple (x, y), where both x and y can assume different (Roda, 2012), five criteria have been selected as the most values depending upon the type of inventory review (i.e. proper ones for MROs classification: Lead Time, Price, periodic or continuous review) and the optimal order size. Turnover Rate, Stock out cost and Specificity. Literature is full of proposed inventory control models After the implementation of the AHP methodology, the but each of them seems to be presented, in most of the spare items are then classified with respect to an overall cases, without an explicit connection with the peculiarities index, which takes into account more than one criteria, of the spare parts for which it is recommended to be and the items’ criticality profiles are also available. It is applied to. No or few works in fact speak about the now possible to carry on with the next step dealing with applicability of the inventory control models they present, the selection of inventory control models: the idea is to referring to spare parts different characteristics. For this assign the proper control model to criticality profiles; to work concern, 4 inventory control models are considered this end, the applicability conditions for each control and studied in their applicability: (i) the continuous review, model are analysed, in order to fit the inventory models with fixed reorder point (r) and fixed order quantity (Q), features with the criticality profiles. referred to as (Q, r); (ii) the continuous review, with fixed re-order point (s) and order-up-to level (S), referred to as 4.2 Applicability of inventory control models (s, S); (iii) the periodic review, with fixed ordering interval (T) and order-up-to level (R), referred to as (T,R); (iv) the The idea at the basis of this paper is to find proper models continuous review and order-up-to level (S) in a one-for- to manage stocking and purchasing of maintenance items, one replenishment mode, referred to as (S-1, S). considering that within a stock there are several different classes of spares, each one with their own peculiarities. In Specifics about the algorithms on which the models base particular, by referring to the categorization of the actual on are not presented in this paper: plenty of literature stock of a company, resulting from the classification step, works can be found about this issue. On the other hand, a this step now aims at the selection of the best model to discussion is herein presented for what concern their manage each class of spares / each critical spare item. A applicability: this aims at providing a better focus on the framework is required to this end which, acting as a meta- alignment of the outcomes of spare part classification and model, allows to relate different inventory control models the selection of inventory control. to different characteristics of the spare parts. The framework considers, according to the proposal of 4. Model Definition this paper, the ‘criticality profiles’ of the classes of spares /spares as to drive the selection. Hence, an analysis of 4.1. Using AHP in spare parts classification as a tool for alignment applicability conditions of each inventory model has been As far as the classification step concerns, the objective is undertaken to build the framework, driven by the the definition of a criticality index for each spare item / elements measured in the ‘criticality profiles’. In particular, class of items. Once the criteria to be considered in the the aim has been to identify the peculiarities of the items decision process have been defined, by using the AHP it is to which an inventory model best fits, based on the theory easy to determine the weight that each of them has on the already presented in literature references plus additional final assessment of criticality and to calculate the overall considerations logically derived by a deductive process
  • 5. initiated from the inventory control models’ properties and can be easily found in the market (i.e., mid to low themselves. specificity). For what concern the (Q, r) models, it is widely stated and 4.3 Model development approved in literature that they are implementing policies By structuring the reasoning presented in the previous for fast or normal moving spare items: Gelders and Loony subsection it is possible to finally define the framework: (1978), for example, empirically demonstrate the classical this is materialized as a matrix able to guide the decision EOQ model as appropriate for normal and fast moving about which inventory control model to be used for a items; Porras and Dekker (2008) also present the (Q,r) particular item’s criticality profile, by referring to the model with normal approximation of the demand as a mode assumed by each criterion for that item (Table 2). suitable model for items with high turnover rate. As far as the lead time concerns, these models are usually applied in C1 C2 C3 C4 C5 Lead Price Turnover Stock Out Specificity case of long lead times (Fera, Lambiase, 2010). Since they Time Rate Cost are based on the continuous review, these models enable (Q,r) Mid/long High Mid/high Mid/low Mid/low to keep the average stock level lower than in the periodic (s,S) Short High Low Mid/high Mid/high review: they are then preferable for high price spare items, (T,R) Mid/short Low Mid/low Low Mid/low because of the resulting lower holding costs. Thereafter, in practice, the (Q,r) models are normally mentioned for (S-1,S) Long High Low Mid Mid/high managing either consumables or generic materials (that is, materials characterized by low or, at most, mid specificity). Table 2. The framework to select inventory control Further on, no particular concern is given to the stock out models starting from the classification outcomes costs: it can be deduced that low/mid stock out costs can be considered as the applicable characteristics. The selection will be guided by the criticality profile which identifies the most critical criteria for a certain item and The (s, S) model is based on the assumption that demand which are the ones to be considered first in the selection behaves as a Poisson distribution; the (S-1, S) model is a of the model. The following steps may be considered: (1) particular case of (s,S) model, with an underlying Poisson consider the criterion with the highest value in the demand distribution as well (Feeney and Sherbrooke, criticality profile composition; (2.) look at its mode (high, 1966). These models are globally proven in literature as medium or low); (3.) by using the framework, select the the best choice for slow moving items. Moreover, the models which can be used for such criterion’s mode models are usually preferred for spares with high price. In (scroll the criterion column and select the rows where the particular, (S-1, S) model is the most appropriate when value in the cells corresponds to the mode assumed by the demands and order costs are relatively low, and the spares’ criterion); if the models (rows) selected are more than 1, prices are high (Rose, 1972), especially when the lead time go to step 1, else stop. is long. On the other hand, the continuous review of the (s, S) model fits well with items characterized by a short 4.4 An example lead time (Duchessi et al., 1988). In practice, these models A short example in order to clarify the usage of the model are usually mentioned for stocking specific materials (that developed in the paper is herein given. After using AHP is, materials with a mid/high specificity) and in case of for classifying the components of the combustion system mid/high stock out costs (this is mentioned especially for of a mining truck’s engine, the overall criticality index the case of (s,S)). obtained for each of them allows to identify the most The (T,R) model is run in the common use particularly in critical one, that is the fuel tank. The radar chart in Figure companies not utilizing computerized control. This is also 4 shows the criticality profile of that item. frequently seen when the spare items are ordered from the C1: LEAD TIME 0,4 same supplier, or require resource sharing. Because of the 0,3 periodic review, this model leads to higher stocks, then 0,2 C5: SPECIFICITY C2: PRICE higher holding costs, than the continuous review: this is a 0,1 reason why the (T,R) model can be better justified for low 0,0 price items. With higher stocks, mid to low turnover rates are expected for the model: this depends on the demand rate, not high with maintenance materials. Differently to C4: STOCK OUT COST C3: TR the ones above, in this case the order quantity is not fixed Figure 4. Fuel Tank’s criticality profile but the inventory level is restored to its maximum value each replenishment period: this approach is simple and usually applied for not very critical parts in term of stock From the criticality profile (see Figure 4) and the criteria out costs. In practice, the periodic review can be justified modes assumed by the item (see Table 3), it is then also for what concern the lead time: with mid/short lead possible to select the inventory control model, by using time, the periodic review is acceptable, while not being the framework (of Table 2). forced to implement a computerized control to keep C1 C2 C3 C4 C5 stocks under a continuous review. This is often Lead Price Turnover Stock Out Specificity Time Rate Cost accompanied by the fact that materials are quite generic Long High Low High Mid/High Table 3. Fuel Tank’s criteria modes
  • 6. Starting from the criterion with the highest weight in the capacity, European Journal of Operational Research, 97: 480- overall criticality index (i.e. the lead time) and following 492. the algorithm presented in the previous section, the (S- Duchessi P., Tayi G. K., Levy J. B, A (1988) ;Conceptual 1,S) model is selected as the most proper one. Approach for Managing of Spare Parts, International Journal 5. Conclusions of Physical Distribution & Logistics Management, Vol. 18 Iss: 5, pp.8 – 15 The major problem, for the framework developed in this paper to be more consistent and solid, stands in the Feeney G. J., Sherbrooke C. (1966), The (S-1,S) Inventory paucity of research with an integrated perspective on spare Policy under Compound Poisson Demand, Management parts management: as evidenced from literature review, an Science, Vol. 12, No. 5, A ,Sciences, 391-411 approach integrating spare parts classification, demand Fera, Lambiase Nenni (2010), A Proposal for Estimating forecasting, inventory control models and performance the Order Level for Slow Moving Spare Parts Subject to measurement is hardly present in literature. In order to fill Obsolescence, iBusiness, 2, 232-237 this gap, in this work a deductive process has been used with the aim of handling the few information from Gajpal P. P., Ganesh L. S. (1994), Criticality analysis of literature about differentiated ways of managing spare spare parts using the analytic hierarchy process, parts in the most consistent way in order to obtain the International Journal of Production Economics, Vol. 35, Iss 1- framework. Of course, this methodology is useful to 3,pp 293-297 create the basis for the definition of a model; building of more theory is necessary to define a complete and robust Gelders L.F., Van Looy P.M. (1978), An Inventory Policy framework. In particular, detailed and focused empirical for Slow and Fast Movers in a Petrochemical Plant: A investigations are required in the next future for validation Case Study, The Journal of the Operational Research Society, of the framework: case studies and proper testing, such as Vol. 29, No. 9, pp. 867-874 with simulation, to verify the adaptation to a real setting Huiskonen (2001), Maintenance spare parts logistics: of the framework, will be required. This will help studying Special characteristics and strategic choices, International different scenarios and validating models, considering also Journal of Production Economics, Vol71, Iss1-3, 6, pp125-133 the dynamics in the application in a real industrial world. Kennedy, WJ, Patterson, JW, Fredendall, LD. (2002) , An Acknowledgments overview of recent literature on spare parts inventories, International Journal of Production Economics, 76(2): 201–215. This paper grounds on a research supported with the project “Dote Ricerca applicata: MeS-MaM - Metodi e Labib A.W., (1998) World-class maintenance using a Strumenti per la riduzione dei costi di gestione dei computerised maintenance management system, Journal of Materiali di Manutenzione” (in English: Methods and Quality in Maintenance Engineering, Vol. 4 Iss: 1, pp.66 - 75 tools for the reduction of cost of spare parts). The project Molenaers A., Baets H., Pintelon L., Waeyenbergh was funded by Regione Lombardia (Lombardy Region) G.(2011), Criticality classification of spare parts: A case and ABB Spa Process Automation Division. The authors study, International Journal of Production Economics (to be would like to thank the other persons that contributed to published). the project, namely Eng. Federico Curcio formerly M.Sc student from Politecnico di Milano and Eng. Salvatore De Porras, Dekker (2008), An inventory control system for Angelis project manager from ABB Spa Process spare parts at a refinery: An empirical comparison of Automation Division. different re-order point methods, European Journal of Operational Research 184 pp.101–132 References Roda I. (2012), An integrated decision framework for Bacchetti A., Saccani N. (2011), Spare parts classification Spare parts classification and Inventory control policy and demand forecasting for stock control: Investigating selection: Conceptualization, development and validation the gap between research and practice, Omega, Vol40, Iss6, in industrial contexts; MSc Thesis (Politecnico di Milano) 722-737 Rose M. 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