Surviving the Spare Parts Crisis. Joel Levitt

Чтение книги онлайн.

СКАЧАТЬ

      Maintenance Policy Leads to the Stocking Policy

      The Product of Maintenance Is Reliable Capacity

       8 The Big Picture: Where the Maintenance Warehouse Fits

      ISO 55000 Asset Management Programs

      Purchasing MRO Spare Parts

       9 Storeroom Management

      Business Processes and the Storeroom

      Warehouse Management Activities

      Kitting

      How Do We Get Accurate Records?

       10 Computerization

      Inventory Computer System: A Project

      Bill of Materials (BOM)

      Building the Parts Files in the CMMS

      The Parts Catalogs

      Rules of a Computer-Aided Maintenance Storeroom

       11 The Physical Storeroom

      Functions of the Physical Storeroom

      Where to Locate the Storeroom

      Sizing the Storeroom

      Care and Feeding of Spare Parts

      Hazardous Materials Management

      Storeroom Layout Strategies

      How to Conduct a Physical Inventory

      5S and Your Storeroom

      Hoarding and Pirating of Inventory

       12 The Economic Storeroom

      Accounting for Spare Parts

      Types of Demand

      Different Models to Accommodate Demand

      Carrying Costs

      Economic Analysis: Big Ticket Analysis

      Obsolete Parts and Gross Overstock

      Managing Inventory Turns

      The Call for Lean

      How Service Level Contributes to the Spare Parts Crisis

      Lead Time

      Cost of Stocking or Procurement (Also Known as Cost of Acquisition)

       13 SIC (Statistical Inventory Control)

      Calculating Safety Stock

      Economic Order Quantity (EOQ)

      Additional SIC Formulas

       14 Dealing with the Part Itself

      Evaluation of Parts the First Time Around

      Parts Interchange

      Machine and Part Criticality

      Warranty Recovery for Parts

      Know Your ABCs: Segmenting Your Inventory for Analysis

      Time to Failure

      Reverse Engineering

      Counterfeit Spare Parts

      Cost of the Failure of Failure Analysis

       15 Parts as a Business : E-MRO

      The Internet and Savings

      Maintenance Distributors

      The Law: Uniform Commercial Code (UCC)

      Vendors

      Other Strategies

       16 Parts: Replace-Rebuild-Remanufacture-Used

      Replace

      Rebuild

      Remanufacture

      Used

      Remanufacture versus Replacement of Entire Machines

       17 Metrics and KPIs for the Maintenance Warehouse

      Performance Metrics

      The SMART Technique

      Why Measure?

      Warehouse Metrics

      Parts Metrics

      Metrics for All of Maintenance

       18 Bright Future for the Spares Business

      Internet-Based Sourcing

      3D Printing

       Glossary

       Bibliography

       Index

      INTRODUCTION

       DID YOUR MANAGEMENT TELL YOU THAT “YOU ARE ALREADY A HERO”?

      You are already cutting the inventory level before you even get started. Congratulations!

      If you look at inflation in prices of parts over the last decade or two, you can see that parts prices have inflated faster than wholesale prices, consumer prices, or most other inflation metrics.

      What that means is that bravely holding the line on the maintenance inventory is equivalent to a 5–10% annual decrease in inventory. That might not sound like a lot, but it does accumulate over time. Therefore, a $2 million inventory today is equal to a $1 million inventory just 10 or so years ago.

       THE VOCABULARY OF STORES, STOREROOMS, PARTS WAREHOUSES, AND INVENTORY

      Every field has words that mean special things. Although the jargon of a field can be (quite) challenging to outsiders, it allows practitioners to speak to each other quickly and accurately. The glossary in the Appendix provides a slew of definitions for the storeroom world’s special language. Understanding this special vocabulary is essential to understanding the field.

      Note that for our purposes, the terms storeroom (stockroom, parts room) and warehouse (parts warehouse) are synonymous; they will be used interchangeably in this book to describe the parts storage СКАЧАТЬ