What Is Spare Parts Management?

Spare Parts Management When maintaining and repairing equipment, new parts and repair parts used to replace parts that have worn out or become unusable or damaged are called parts. In order to shorten the downtime of equipment repair, a certain number of spare parts are purchased, manufactured and stocked in advance. Spare parts are the main material basis for equipment repair. Supplying spare parts in time can shorten repair time and reduce machine losses. Supplying high-quality spare parts can ensure repair quality and repair cycle and improve equipment reliability. Therefore, spare parts management is the main component of equipment maintenance resource management.

Spare parts management

The purpose of spare parts management is to use the minimum spare parts funds and reasonable inventory reserves to ensure the need for equipment maintenance and continuously improve the reliability, maintainability and economy of the equipment. ^[1]

(1) Provide qualified spare parts to maintenance personnel in a timely and effective manner. To this end, it is necessary to establish a corresponding spare parts management organization and necessary facilities, and scientifically and reasonably determine the reserve variety, form, and reserve quota of spare parts, and do a good job in the storage and supply of spare parts.

(2) Focus on the supply of spare parts required for key equipment maintenance. Enterprises

The content of spare parts management can be divided into the following four items according to their nature:

1. Technical management of spare parts

The technical management of spare parts is the basis of spare parts management. It mainly includes:

1. Leaders value and prepare carefully

In order to ensure the normal operation of the equipment, the leader attaches great importance to the management of spare parts. In the initial stage of production preparation and commissioning, a spare parts research group with the equipment factory leader as the team leader was established to organize relevant engineering and technical personnel to intervene in advance, familiarize with the equipment, and understand the Technical parameters, principle structure, conversion and preparation of spare parts drawings, timely submission of spare parts plans, and actively organize supply. During the normal production phase, regular equipment meetings are held regularly to organize and coordinate the management of spare parts according to the operation and transformation of the equipment.

2. Improve "Equipment of Equipment and Spare Parts" and grasp the core of spare parts management

According to the actual situation of the equipment, for each piece of equipment, establish four categories of "Equipment for Equipment Spare Parts" such as special machinery parts, general machinery parts, power universal parts, electrical spare parts, etc., and specify the names and drawing numbers of spare parts | With standards, models and specifications, main technical parameters, simplified diagrams, maximum and minimum reserve quotas, actual inventory, inventory locations, reference prices and other spare parts information, and continue to modify, and gradually form a more comprehensive technical information of spare parts management, for spare parts Management of plans, inventory, quotas, funds, and statistical analysis provides technical basis to facilitate the personnel of the mobile department, workshop, and team to grasp the status of spare parts.

3. Actively do a good job of technical management of spare parts

Some of the equipment drawings of the plate mills are in German, Dutch, or English, some in German or American standards, some in assembly drawings without parts, some without drawings, and some standard parts are not standard. In order to solve these problems, the following measures have been taken to solve the problems of the same equipment spare parts.

(1) Unified drawing number. One type of spare parts is the only figure number in the form of HB *-*-*-*-, which runs through the life of the spare parts. HB stands for the plate factory, and the four * in turn reflect the professional category, equipment, location, and spare parts sequence. .

(2) Adhere to the standardization, generalization and serialization of spare parts.

All adopt national standards and ministerial standards to select, design and manufacture spare parts, and minimize the variety of spare parts; a large number of different and similar equipment spare parts such as crane wheels, reducers, synchronization shafts, straightening machine slides, hydraulic cylinders, etc. Modify the design and gradually move closer to each other to make the spare parts unified and interchangeable. According to the same design standards, spare parts with the same structure, same function, different sizes and technical parameters, such as gear couplings, reducers, and single-pass rollers And so on, arranged according to a certain law, constitute a series of spare parts.

(3) Actively localize spare parts. Since two thirds of the entire plant is old equipment, a large number of spare parts are needed, such as straightening rollers for thermal straighteners, main reducers, cold bed drawing steels, reducers for flap mechanism, slitting eccentric shafts, gears, and transverse shear These spare parts are all foreign language drawings, and ordering foreign spare parts is expensive, has a long cycle, and is inconvenient to supply. Therefore, you should actively do the translation of foreign language drawings, domestically design and manufacture spare parts, and pay full attention to Changes to standards, materials, and processing techniques have enabled spare parts to meet original structural and technical performance.

(4) Actively adopt new technologies, new processes and new materials to increase the life of spare parts. For example, wear-resistant copper slides are used in actual work to increase the service life of the universal joint sleeve slides of four-roll rough rolling mills; welding repairs are used to repair shafts with severe wear; laser surface treatment technology is used to treat the cutting edges to make To multiple reuse.

(5) Actively develop spare parts. For the spare parts without drawings or unclear and incomplete drawings, use the time of daily maintenance, overhaul and repair to carry out surveying and mapping, research and prepare parts, and draw drawings.

(6) Strengthen the repair and utilization of spare parts through reward and assessment measures. Due to the low stock of spare parts, according to the operation of the equipment, the timely and urgently needed spare parts such as motors, reducers, universal joint sleeves, etc. are actively used for welding, repair, and processing, and reused to ensure the equipment operation , And reduce the consumption of spare parts.

(7) Make drawing management. A spare part drawing is unique, and the drawings and objects are consistent; the spare part drawing is sent to the workshop and the team in time to make it a technical basis for the common use of spare parts and equipment maintenance; the equipment and spare parts are scrapped, and the drawings must be destroyed; Spare parts drawing cabinets must co-exist with blueprints and base drawings. Frequently used spare parts should always have blueprints.

4. Strengthen the planning and statistical analysis management of spare parts

Spare parts plan is the basic basis for organizing the production and supply of spare parts. In practice, there are monthly plans, additional plans, annual plans, and major and intermediate repair plans. The focus is on the management of monthly spare part plans.

In order to ensure the rationality and accuracy of the spare parts plan, to ensure the timely supply of spare parts according to the plan, the rational use of spare parts funds, and the accelerated turnover of spare parts inventory funds, when preparing the spare parts plan, pay attention to two points:

(1) Fully understand the operation and maintenance of the equipment.

(2) Grasp the consumption quota and reserve quota of spare parts, the carry-over amount of orders, the inventory of spare parts, and the order cycle of spare parts.

At the same time, the spare parts plan is dynamically tracked to keep abreast of the processing and supply of spare parts.

In order to strengthen the management of spare parts and reduce the cost, the statistics of the spare parts inventory index, consumption index and repair index should be actively carried out to provide a decision basis for the management of spare parts and a reference basis for the development of a spare parts work plan.

5. Strengthen the inventory management of spare parts

In order to strengthen the management of spare parts inventory, the following measures have been taken:

(1) According to the requirements of the ISO9002 standard, when the account card is matched, there must be a card for something, a card for a card, and a card for a card.

(2) The storage of spare parts must be checked and accepted by the spare parts staff, regional technicians, and warehouse administrators. When entering the warehouse, it must be stored in the designated area, and the card must be established and the account established.

(3) The supply of spare parts adheres to the limited supply system, and they are collected at the warehouse with the receipt.

(4) Timely clearance and inventory checking.

6. Strengthen the quota and fund management of spare parts

In order to reduce the flow | examination big | capital occupation, reduce production costs, accelerate capital turnover, according to the operation of the equipment, adopt scientific and reasonable methods to timely formulate and timely modify the quota of spare parts:

(1) According to the manufacturing cycle of the spare parts, the optimal processing cycle, the occupancy of the spare parts, the service life, the correction factor, etc., the reserve quota of the spare parts is reasonably formulated, and the inventory of spare parts is well controlled to prevent the phenomenon of over-reserve.

(2) The principle of meeting production needs is based on the output, equipment status, spare parts life, and actual consumption levels over the years, and reasonable consumption consumption quotas are set.

Accurately set the quota of spare parts funds and strengthen the management of spare parts funds.