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Theme
Planning and controlling the maintenance
spare parts becomes a very complex task
as the number of parts increase with
time and variety of equipments are added
to the plant.
In majority of the cases the problem is
compounded as more popular techniques
suitable for fast moving production
items are sought to be used for spares.
Spare parts require definitely a
different approach which takes into
account criticality and plans
availability according to criticality.
Spare parts manager has to recognize
importance of identification and hence
the complexity of codification,
lifecycle of an equipment and cost
implication of the decisions related to
stocking. The spare parts supplies by an
equipment manufacturer is the other side
of coin which has concerns of several
business related issues like warranty
cover, distribution, product lifecycle,
design changes and cost of service.
Understanding of the issues would allow
one to develop a robust and logical
policy and procedure to manage the spare
parts service.
The program is designed to bring up all
the issues to develop a comprehensive
perspective for the same.
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Program
Schedule: Day 1: 9-00AM to
5-15PM+ |
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Introduction
Participants and faculty
introduce themselves and issues
of participants interest are
listed
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Maintenance
activity
Basic concepts about life cycle
of the plant/ equipment, planned
service, planned shutdown,
annual turnaround, major or
minor overhauling, recharging,
breakdowns/ failures Induction
of the plant and machinery in
the system, manufacturers
maintenance manual, service
schedule, requirement planning/
requisitioning, maintenance
service reports, systems of
issues and returns for
consumption of parts as well as
rotable spares, MTBF.
Stores - Large variety
and small quantities, physical
identification, storage system,
importance of location, issues
of preservation, distribution of
common items
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Planning
for replenishment
Supply and suppliers, lead-time,
costs, risk of stagnant
inventory, obsolescence,
movement characteristic of
maintenance spares, four basic
types of consumption patterns
and suitable approach for them
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Case
discussions
Participants read and discuss
cases in groups; faculty
facilitates the discussion to
list out the learning (4 cases
of common interest)
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Computerized maintenance
management system
The plant and equipment, systems
of codification, the asset
management module, maintenance
module with job accounting
system, the stock management
module
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Program
Schedule: Day 2: 9-00AM to 5-15
PM+ |
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Consumables
and expendables
Patterns of consumption,
physical storage and issues and
associated problems, P and Q
systems, ABC analysis based
optimization
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Long
interval and discrete
consumption
Shutdowns, overhauls and service
requirements, stockless
operations for fixed interval
items, concept of insurance
spare |
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Breakdown
spare parts
Erratic consumption pattern,
high consequences of
non-availability, alternatives
to stocking, collective
stocking, consumption based
payment contract, criticality
based service, VED analysis,
application of Poisson
distribution for planning,
adoption of inventory policy
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Exercises
3 typical cases of regular
consumption item, insurance
spare and breakdown spare
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After-sales
repair and maintenance spare
service
OE support system, warranty
support, lifetime support,
Criticality and service
categories, obsolescence, impact
of population of equipment on
planning, insurance spare
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Q & A |
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Home
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