The purpose of spare parts management is to improve the reliability, maintenance and economy of equipment with minimal funding for spare parts, a reasonable stock reserve, and the need for equipment maintenance。
And to do the following
(1) minimize the loss of stoppage caused by equipment failure。
(2) reduce to a minimum the stop time and repair costs of planned repairs to equipment。
(3) compress the reserve funds of the spare parts bank to a reasonable minimum。
Coverage of spare parts management measurement indicators
Based on the above requirements, the management of spare parts is guided by the 12-word management principle of “continuing, non-defeating, non-stocking and consumption”. Specific measurement indicators are described in the book spare parts management for automobile equipment as follows:
Ongoing - one time fill rate
The “continuing material” includes requirements for the timeliness and availability of spare parts, as well as feedback on the level of services provided by spare parts. Timeliness of supply: type, quantity of spare parts that can be provided in a timely manner to meet requirements; availability of spare parts: functionality and quality of spare parts are in line with usage requirements。
One-time compliance rate offr = 100 per cent of total monthly spare parts requirements per month
Unnecessary — spare parts stock turnover ito (inventory turnover late)
Uncertainties in the use of spare parts throughout the maintenance process have determined the need to increase, to the extent possible, the projected impact rate for spare parts and to reduce the number of spare parts that are not mobile in the warehouse。
Spare parts stock turnover ratio ito = 100 per cent average monthly cost of spare parts consumed/month inventory*
Of which average monthly inventory = (at beginning of month + end of month)/2
Non-assembly — spare parts stock amount ia (inventory amort)
Establishment of a reasonable stock of spare parts, non-assessing of spare parts, taking advantage of liquidity and reducing the stock of spare parts to a reasonable supply level。
The stock turnover rate reflects the liquidity of inventory spare parts, the amount of which is a direct reflection of the size of the total inventory occupancy fund and, indirectly, the economy of the utilization of the funds, which is more economical when the stock turnover is the same。
Depletion — cost of spare parts for repair of single vehicles (maintenance cost per unit)
The overall cost of operation of the equipment is reduced by seeking a maintenance strategy that is appropriate to current operating conditions, an economic maintenance strategy, an optimized procurement strategy, the reuse of spare parts maintenance, an increase in the lifetime of spare parts and a reduction in the overall consumption of spare parts。
Spare parts for repairs per vehicle = monthly maintenance of spare parts materials/month total production vehicles per unit
Main mission report
(1) timely and effective provision of qualified spare parts to maintenance personnel. This will require the establishment of appropriate spare parts management structures and the necessary facilities, as well as the scientific and rational determination of the types, forms and quotas for the storage of spare parts and the supply of spare parts。
(2) focus on the supply of spare parts for critical equipment maintenance. As the enterprise's critical equipment has a significant impact on the production and quality of products, the management of spare parts focuses first and foremost on meeting the needs of critical equipment for the maintenance of spare parts, ensuring the proper functioning of critical equipment and minimizing downtime losses。
(3) information gathering and feedback on the use of spare parts. Spare parts management and maintenance personnel are required to continuously collect qualitative and economical information on the use of spare parts and to provide timely feedback to spare parts technicians in order to improve and improve the performance of spare parts。
(4) reduce, to the extent possible, the use of funds for spare parts, subject to guaranteed availability of spare parts. Spare parts managers should endeavour to plan, produce, procure, supply and keep spare parts, reduce the funding for spare parts reserves and reduce the cost of spare parts management。
Report on work
The elements of spare parts management, by their nature, can be divided into the following four elements:
1. Technical management of spare parts
Spare parts management
The technical management of spare parts is the basis for the management of spare parts, which includes, inter alia, the collection of spare parts drawings, mapping and preparation of spare parts drawings, and the design and preparation of basic information such as statistical cards and reserve quotas for all categories of spare parts。
The planned management of spare parts refers to the phase from the preparation of spare parts plans to the filling of spare parts, including, inter alia, the monthly self-generated spare parts plan, the annual and batch plans for out-of-pocket purchases, requests for casting, exercise bracing items, the manufacturing plan, the spare parts purchase and processing plan, the preparation and organizational implementation of spare parts rehabilitation plans。
3. Spare parts warehouse management
Spare parts warehouse management refers to the period from the filling of spare parts to the issuance phase, which includes, inter alia, inspection of spare parts warehousing, maintenance, registration of cards, upshelter storage, collection, dispatch and safekeeping of spare parts, control of booking points and stock levels, statistical analysis and control of spare parts consumption, fund occupancy and turnover, collection of information on the quality of spare parts, etc。
4. Economic management of spare parts
The economic management of spare parts refers to the economic accounting and statistical analysis of spare parts, including, inter alia, the approval of funds for spare parts inventories, the management of access bank accounts, the validation of the cost of spare parts and the statistical analysis of the various economic indicators for spare parts, which should permeate the entire process of the management of spare parts, while the quality and level of conditions management should be measured by the statistical analysis of the economic indicators。
Effective measures for reporting
Leadership attention, careful preparation
In order to ensure the proper operation of the equipment, the leadership attaches great importance to the management of spare parts. In the early stages of production preparation and commissioning, a spare parts clearance team, headed by the head of the plant, was set up to organize early intervention of the relevant engineering technicians, familiarize themselves with the equipment, understand the technical parameters of the equipment, the rationale structure, convert and prepare spare parts drawings, present spare parts plans in a timely manner and actively organize supplies. During the normal production phase, regular meetings of equipment are held to organize coordination of spare parts management, depending on the operation and adaptation of the equipment。
2. Refinement of the equipment spare parts account to capture the core of spare parts management
Based on the actual condition of the equipment, four main categories of equipment spare parts, namely, mechanical specializeds, mechanical utility, power utility, electrical spare parts, are set up for each equipment, detailing the name of the spare parts, graphs and graphs, sizes and specifications, key technical parameters, diagrams, maximum and minimum reserve quotas, actual stock levels, storage locations, reference prices, etc., and are continuously revised to develop better technical information for the management of spare parts management, providing the technical basis for the management of spare parts plans, stocks, quotas, funds, statistical analyses, etc., so as to facilitate the control of spare parts by the mobile sections, workshops and teams。
3. Active technical management of spare parts
The following measures have been taken to address the problems of equipment drawings at the medium-heavy mill, either in german, dutch or english, or german or united states standards, with only assembly plans without spare parts, with no drawings at all, with some standard pieces not standard, and with the same equipment spare parts not uniform。
(1) uniform chart numbers. A unique designer of spare parts, such as hb*-*-*-*, has been used throughout the life cycle of spare parts, and hb represents the medium-heavy plate factory, with four* in turn reflecting the professional category, the equipment to which it belongs, the parts to which it belongs, and the spare parts sequence。
(2) maintain standardization, interoperability and serialization of spare parts。
All parts are selected and designed using national standards, departmental standards to minimize the variety of spare parts; a large number of different and similar equipment spare parts, such as wheel wheels, speed-reducing machines, synchronized axes, proper taxiways, hydraulic cylinders, etc., are designed in such a way as to bring each other closer to one another, so that spare parts are uniform and interchangeable; and, according to the same design criteria, spare parts with the same structure, functions, different sizes and technical parameters, such as gear axes, speed-reducing machines, one-way circuits, form a spare parts series in a sequenced fashion。
(3) active nationalization of spare parts. Since 2/3 of the plant-wide equipment is old, and requires a large number of spare parts, such as the calibrated rectangular of the heat-resort, the main speed-reducing machine, the cold-bed steel-stretching machine, the pericardial axes, gears, cross-cutting main drive boxes, etc., all of which are foreign-language drawings, and the cost, cycle and supply of spare parts abroad are expensive, unserviceable, the translation of foreign-language drawings should be actively undertaken, the national design, manufacture of spare parts and due regard to changes in standards, materials and processing processes so that spare parts meet their original structural and technical capabilities。
(4) actively introduce new technologies, processes and materials to improve the lifetime of spare parts. In practice, for example, the use of milled copper skateboards to increase the lifetime of the four-roller corroders, the use of welding techniques for the repair of badly worn axes, and the use of laser surface treatment techniques for the treatment of blades for multiple reuse。
(5) actively develop spare parts. Undefined and undetailed spare parts without drawings or drawings are used for mapping, spare parts are developed and drawings are prepared using day-to-day time of overhaul and major repair。
(6) enhancement of the use of spare parts for rehabilitation through incentives. Owing to the low stock of spare parts, and based on the operation of the equipment, the supply of late and urgently needed spare parts, such as electrics, speed-reducing machines, axles, etc., has been actively reused through welding, repair, processing, etc., both to ensure the operation of the equipment and to reduce the consumption of spare parts。
(7) make good drawing management. A spare parts drawing board is the only one that matches the drawings and items; spare parts drawings are released from the spare parts distribution workshop and teams in a timely manner as a technical basis for the use of spare parts and the maintenance of equipment for mutual compliance; equipment, spare parts are scrapped and drawings must be destroyed; and specialized spare parts drawing cabinets are set up in the archives, which must coexist with blueprints, floor maps and frequently available spare parts blueprints。
4. Strengthening spare parts planning and statistical analysis management
The spare parts plan is the basic basis for organizing the production and supply of spare parts and is applied in the form of monthly plans, supplementary plans, annual plans, major and medium-sized plans, with emphasis on the management of the monthly spare parts plan。
In order to ensure the reasonableness and accuracy of spare parts plans, ensure the timely supply of spare parts as planned, rationalize the use of spare parts funds, expedite the liquidity of spare parts inventories, and in preparing spare parts plans, focus on two points:
(1) full knowledge of the operation and overhaul of the equipment。
(2) maintenance of consumption and reserve quotas for spare parts, order carry-over, spare parts stock, spare parts ordering cycle。
At the same time, the spare parts plan is being kept abreast of the processing and supply of spare parts。
In order to strengthen the management of spare parts and reduce costs, statistics on spare parts inventory, consumption and rehabilitation indicators should be actively undertaken to provide the basis for decision-making on the management of spare parts and for the planning of work on spare parts。
To strengthen spare parts inventory management, the following measures have been highlighted:
(1) as required by iso 9002, the entry card must be in conformity with the card, the card must be in writing and the account must be in writing。
(2) the inventory of spare parts must be carried out jointly by the spare parts clerk, the regional technicians and the warehouse manager for quality inspection and inspection, and must be stored in accordance with the assigned area and provided with cards and accounts。
(3) spare parts are issued on a limited supply basis and received from the warehouse on the basis of a receipt。
(4) timely inventory。
6. Enhancement of quota and fund management for spare parts
In order to reduce the high cost of mobile tests, reduce production costs and accelerate the liquidity, the spare parts quotas are established and revised in a timely and scientifically sound manner, depending on the operation of the equipment:
(1) rationally set reserve quotas for spare parts based on their manufacturing cycle, optimal processing cycle, spare parts occupancy, useful life, correction factor, etc., and well controlled spare parts holdings to prevent overstocking。
(2) the consumption of spare parts is based on production, equipment status, spare parts lifetime and actual consumption levels over time, based on the principle of meeting production needs。
Accurate funding quotas for spare parts and strengthen management of spare parts funds。
