Sparing to Availability
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Proper planning and control of spare parts inventory is a critical component of an effective asset management program. If the correct parts are not on hand when needed for routine maintenance or repairs, downtime is prolonged. If too many parts are on hand, the enterprise absorbs excessive costs and the overhead of carrying the inventory.
Management of spare parts is often not optimal. In many cases, the value of low-used and unusable parts can be more than 30% of the total value of parts stored. The S2A module checks all spare policies against the required system availability.
It recommends the optimal number of spares for multiple possibility stock sites (Source Exchange and Forwards) in the maintenance site map. System availability is achieved for each part number required and its physical location. The S2A enables minimizing the total cost of spares purchased, initially and during lifetime, taking into account repair sites, repair delay time (if applicable), the transportation, packing, down time costs and others.
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Key benefits of the S2A module
- Reduces and optimizes inventory costs
- Evaluates 'pooling' options and shared stock strategies
- Justifies basis for carrying inventory for certain required availability
- Compares alternative vendors and supply routes
- Reduces the risk of running out of stock
- Optimizes the appropriate purchasing schedule of spare parts
Benefits in the design phase:
- Creates the basis for spare parts quantity to support customer Service Level Agreement (SLA)
- Assists designers to evaluate spare parts cost and quantity during system life cycle
Benefits in the maintenance phase:
- Provides the basis for creating initial and yearly spare part quantities
- Enables maintenance personnel to identify logistic problems within the supply chain
- Calculates quantity spares for each part number in each stock, providing all required availabilities. The stock site for each block can be defined by user or by ORLA
- Selects the optimal solution providing minimal total cost of spare purchasing, storage, transportation & packaging for all replaceable blocks among all the satisfying solutions
- Calculates maximal achievable availability values for the blocks that the availability requirements can not be satisfied
- Recommends to combine spares with the same part number into one stock location or different locations, according to the least expensive solution
- User can define forward stock in a block replacement site, in addition to central (Exchange) stock locating in any site which provides spares for all blocks of the same part number. If S2A calculates zero spares in a stock, this stock is not recommended
- Considers repair time and delay, spare purchase delay, transportation time, stock delay, mean stock waiting time as a result of possible spare orders queue in the stock
- Considers also sub blocks restoration time (Turn Around Time) in addition to the block repair time for non-replaceable block
- Distinguishes between block reliability models with and without redundancy in the calculation of spare waiting time and sub blocks restoration time
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