Spare parts management is about, how spare parts handling must be systematized and structured to enable efficient inventory management that leads to improved availability and reduces the amount of capital expenditure. Safeguard the future of your midsize business with intelligent predictive asset management processes for more efficient equipment maintenance, increased equipment utilization and better spareparts. In manufacturing, maintenance and operations must work as partners. Plant maintenance module consists of key activities to include inspection, notifications, corrective and preventive maintenance, repairs, and other measures to maintain an ideal technical system. As plant manager, you need to know how to determine which spare parts are needed to make up an effective and comprehensive inventory system.
How do you determine which repair parts are critical. Pdf plant key success factor through spare parts inventory. Maintenance, repair, and operations mro in asset intensive. Several critical factors including effective spare parts management, maintenance approach and continuous improvement is explore along with. To create a snapshot of a plants maintenance program, the plants current performance is assessed. Increase in maintenance cost as more spare parts are required. Efficient spare parts management 8 rules preventive maintenance processes without problems segment your sp portfolio assess the. Spare parts management, abc classification, maintenance store. Jul 25, 2017 practical spare part management is the foundation for reliable plant operation and is crucial to a plant managers success. Introduction the main supporting activities for the efficient operation of a container terminal ct are those of critical equipment maintenance and spare parts inventory management. According to bacchetti and saccani 2011, the estimation from aberdeen research pointed that the total market. A crossfunctional team composed of employees from operations, maintenance. Fleet management is not simply about operating the equipment and keeping it fixed.
Publishers pdf, also known as version of record includes final page. May 2020 maintenance and spare parts management bygopalakrishnan 15 pdf drive search and download pdf files for free. To have multiple spare parts in contingency for a single operating component not only adds to management of spares issues, but dilutes the idea of it or them being critical. The objective of spare parts management is to ensure the availability of spares for maintenance and. In one plant where a project to establish new spare parts lists had begun, an analysis of workorder records showed that 60 percent of all corrective maintenance was carried out on less. The pdf of the erlang distribution is also analytically calculable, let us denote it by. In recent years, the investments in market of spare parts management are growing. A crossfunctional team composed of employees from operations, maintenance, engineering, materials management and safety conducts the first phase of a criticality analysis. Pdf spare parts planning and control for maintenance. The main chapter describes in detail the concept of spare parts inventory management in the selected company with a focus on. Maintenance policy and repair management study guide. Spare parts planning and control for maintenance operations. Correctiv e and insp ection based preven tiv e maintenance generate unplanned spare parts orders. Championing sap plant maintenance at your organization.
Plant maintenance iris project goals integrate plant maintenance with finance, human resources, and materials allow enhanced scheduling and planning for work assignments provide work scheduling as well as management reporting tools improve automated updates to customers about the status of work implement a preventive. Maintenance activities are related with repair, replacement and service of components or some identifiable group of components in a manufacturing plant so that it. Plant engineering four best practices in spare parts management. Maintenance often results in some form of material consumption. Dairy plant management and pollution control pdf book.
Dairy plant management and pollution control language. Maintenance spare parts management needs to be driven by business risk management. Often inventory is inaccurate and not stored properly, which results in. Integrate inventory management with plant maintenance by setting up material masters for inventoried items mm01mm02. You can define a refurbishment order as maintenance order by which you can execute the process of refurbishing damaged equipment. Publishers pdf, also known as version of record includes final page, issue and. Often inventory is inaccurate and not stored properly, which results in ordering parts again. Jul 15, 2019 how your maintenance management software can help. Another vital partnership is maintenance and the maintenance stores.
In the sap gui transactions for the maintenance order, you can display the graphic on the operations tab. Enterprise asset management eam software solutions sap. To achieve a high level of maintenance effectiveness, nothing is more important than getting the right parts to maintenance people at the right time. The initial spare parts list was based on the oem recommendations. Organizational structures contents index the authors. Maintenance management is process where available resources are regulated in a manner that plant and machinery can perform at specific levels. When inventory management methods compliment business risk management and reduce total business risk, then. Efficient plant the source for reliability solutions. Spare parts management, classification, riskanalysis, maintenance. Spare parts management, system availability, decision framework, decision. Spare parts are stored in order to reduce the loss of production time. The benefits of using sensors and iiot technology are well documented in terms of implementing predictive and prescriptive maintenance, improving parts management, and greatly increasing overall reliability and profitability. Safeguard the future of your midsize business with intelligent predictive asset management processes for more efficient equipment maintenance, increased equipment utilization and better spare parts turnovers while lowering local maintenance labor costs and total inventory. Spare parts management, system availability, decision.
In addition, maintenance scheduling can impact production scheduling. The measurement of performance is important because it identifies current performance gaps between. After reading this article you will learn about maintenance management. Spare parts management dispensing an organized maintenance storeroom is one of the key processes which support effective maintenance planning and scheduling and equipment reliability improvement. As plant manager, you need to know how to determine which. Hot cutting and shearing technique which is used in manual or automatic way. This thesis is delimited to spare parts management and inventory. S spare parts management is the process of planning and aligning service parts inventories, resources and processes to ensure optimal customer service and response with minimal. Pdf spare parts planning and control for maintenance operations. The most important spare parts lists are for those equipment items on which corrective maintenance or routine parts replacement is carried out most frequently. About the tutorial sap plant maintenance sap pm is a software product that manages all maintenance activities in an organization.
Practical spare part management is the foundation for reliable plant operation and is crucial to a plant managers success. You can use graphics to select spare parts while working in a maintenance order or task list. What spare parts to keep and how much to keep depends upon. This will increase inventory cost of the maintenance department. Fleet management is very wide in scope and includes the full circle of justification, specification, acquisition, assignment, scheduling, utilization and disposal. Maintenance centered service parts inventory control repub. December 6, 2006 maintenance manual fleet management 41.
Efficient spare parts management 8 rules preventive maintenance processes without problems segment your sp portfolio assess the criticality good forecasting special methods for intermittent demand items asset life cycle good information system 57. What is not always considered is that iiotsensor technology also plays a major role in improving plant safety. The objective of spare parts management is to ensure the availability of spares for maintenance and repairs of the plant and machinery as and when required at an optimum cost. The solution to these problems lies in the systematic spare parts management. Furthermore, maintenance boms provide you with an overview of all spare parts used for the maintenance of a specific technical object, so they make spares planning considerably easier. Experts estimate that organizations can save between 510% on their yearly spare parts inventory costs with a maintenance.
If a part is used in many areas of the plant, and the primary function of the component is vital in each area, then it might make sense to increase the number of spares. Experts estimate that organizations can save between 510% on their yearly spare parts inventory costs with a maintenance management program aka cmms software. You can define a refurbishment order as maintenance order by which. Jul 15, 2014 the solution to these problems lies in the systematic spare parts management. Materials management maintenance and repair 2 maintenance materials management generally in the us, the stores investments as percent of estimated replacement value is 1. The construction of the plant in skutskar began in 1893 and two years later in 1895 the. Usually the consequences of downtime are very costly. Free how to download pdf book full guide outlines of dairy plant management and pollution control module 1. Reduction in product quality and increase in wastage. The power of pareto analysis in maintenance reliable plant. Sap erp supports these key requirements through plant maintenance module and integrated functions including inventory. Pm plant maintenance staff want to see the spare parts cost on each pm order on the real consumption date. Maintenance key performance indicators introduction it is not possible to manage what you cannot control and you cannot control what you cannot measure. Spare parts management is about, how spare parts handling must be systematized and structured to enable efficient inventory management that leads to improved availability and reduces the amount of.
Preventive maintenance principles mit opencourseware. To create a snapshot of a plants maintenance program, the plants current performance is assessed, compared to a set of best practices, and plotted on a spider chart. Maintenance, repair, and operations mro in asset intensive industries. Plant maintenance module consists of key activities to include inspection. Proper use of cmms software reports and inventory management features can help reduce inventory carrying costs as well work order. Spare parts management in sap plant maintenance harish, i would like to track how the percentage of time a part was ordered for a work order and it was in stock. When spare parts and equipment assemblies are identified as critical, the second phase of the decision process begins. May 27, 2014 efficient spare parts management conclusions 56. Technicians like to keep additional spare parts on everything. The benefits of using sensors and iiot technology are well documented in terms of implementing predictive and prescriptive maintenance, improving parts management, and greatly increasing overall. Furthermore, the demands made of plant maintenance teams have. A maintenance bom contains the object numbers of the individual components together with their quantity and unit of measure, and can be assigned to the master. Hi, our accountants do not want to manage spare parts stock, they want that spare parts will be consumed upon gr arrival to the plant consumption copst debit speciofic cost center. In the sap gui transactions for the maintenance order, you can display the graphic on the operations tab page by choosing the pushbutton in the table column spare part and in the operation details by choosing the ve viewer pushbutton.
Evaluating effective spareparts inventory management for. Minmax inventory management and maintenance spares. Spare parts management maintenance manual, maintmaster. To create a snapshot of a plant s maintenance program, the plant s current performance is assessed, compared to a set of best practices, and plotted on a spider chart. To achieve a high level of maintenance effectiveness. Peter drucker performance measurement is a fundamental principle of management. Some of the key functions of sap that support spare parts planning are described below. Dairy plant management and pollution control pdf book agrimoon. Free how to download pdf book full guide outlines of dairy plant management and. According to bacchetti and saccani 2011, the estimation from aberdeen research pointed that the total market size for spare parts management software is over 100 millions dollars in 2005.