Spare parts management

There are a number of issues that must be addressed in the maintenance basics arena in order for a pharmaceutical plant to achieve excellence in maintenance. They are performance measures, work order controls, preventive maintenance, spare parts management, operations/maintenance relations, training/continuing education, and the CMMS. 

At each site the warehouse uses a reorder policy for maximum and minimum stock levels with a reorder threshold level established for each item stocked. The maximum, minimum, and reorder levels are based on the initial experience of spare parts management from JACADS with modifications based on ongoing continued operating experience at active facilities. One site had a goal of 98 percent parts availability, and that goal is currently being met. 

With 4 X 50%, the single components are smaller and less expensive. Therefore the costs related to the spare parts management are also reduced. 

Rustenburg, W. D., G. J. van Houtum, and W. H. M. Zijm (2001). Spare parts management at complex technology-based organizations an agenda for research. International... 

Warehousing (node 5). It aims at describing the efficacy and the efficiency of the maintenance spare parts management. 

Information such as yield, energy consumption or personal costs helps to overview a process continuously during operation and to deal with spare parts and raw materials. This so-called supply chain management is now widely accepted. The predominant supplier of business software SAP claims to have given more 21 000 licenses to companies which use their management tools for business and production management [27]. 

Special costs. Special costs include land, spare parts, inspection, project management, chemicals, miscellaneous supplies, and office and laboratory furniture. For preliminary estimates, these costs can be estimated as 4% of the cost of the process units, storage, steam systems, cooling water systems, and offsites. Engineering costs and contractor fees are included in the various individual cost items. 

Maintenance is a vital component of all pilot plant and plant manufacturing operations. Any organization that strives to meet deadlines for the preparation of clinical supplies and commercial APIs requires a plant that ideally does not break down. To achieve this, all responsible managements require a strong, well-staffed maintenance department that has the trained manpower, budget, spare parts, mission, and organization to keep the plant operating. 

Process safety management is the primary requirement that drives process plants and refineries to establish quality control programs for incoming materials and spare parts. OSHA 29 CFR 1910.119 has defined regulations for process safety critical equipment and systems that include such requirements. Other reasons for quality control programs may be equally important, for example when failure has a significant impact on capability to make product or leads to excessive maintenance costs. 

D. Spare parts (stores) management Getting the right spare part to the right place on time is an important step in effective maintenance materials management. Cost-effective pharmaceutical plants employ proper systems, procedures, and practices relating to the procurement and management of maintenance spare parts. Size of spare parts inventory... 

Tlie manager at the plant commented The new Eco Filter w orks very w ell, it is an extremely strong filterw ell-suited for oui application. Running the machine is very easy for operators as w ell, and our spare parts costs have decreased dramatically, ... 

Essential to the continuing operability of the processing equipment is the requirement to maintain adequate stocks of spare parts to allow maintenance as equipment performance deteriorates from age or other causes. This section provides a description of the spare or replacement parts program on a facility and programmatic basis. The committee examined how the systems for managing the spares inventory function currently and how these systems might need to be improved for continuing operations. 

At present, control system spares are supported by an external contractor other spare parts are managed on a site-by-site basis, with provision for sites to get spares from other sites in the event of a local shortage in inventory. 

This function deals with the information associated with the management of finished goods and spare parts after manufacture and before final delivery to the customer. 

For certain products made-to-order (both made-on-demand and option-to-order), the distribution center approach is used because it facilitates planning and use of delivery resources and usually because a sizable part of the manufacturer s product line (such as spare parts) is made to stock. In these cases, the information managed is similar to the made-to-stock case, but actual demand and safety stock concerns are replaced by tracking specific customer orders. Customer orders are part of shipments up to the final distribution center, and final delivery to customer is tracked from there. 

The management of vehicle fleets, for enterprises that have their own, enteiils the capture of maintenance and spare parts information and the capture of vehicle staffing, routes tmd schedules, and current orders, states, and locations. In general, the activities are the same as those of contract shipping organizations, but the manufacturer s transportation fleet has only one customer and usually a small and mainly predefined set of destinations. 

Execution activities supported by transportation include movement of parts between memufactur-ing centers and movement of spare parts and finished products to customers and distribution centers, all of which are revenue producing. The supporting activities of managing transportation fleets and services are also supported. 

Management of spare parts and materials storerooms and inventories... 

Standard POs that include the conditions of sale for medical equipment are usually used to initiate the order. At the time the order is placed, clinical engineering is notified of the order. In addition to current facility conditions, the management must address installation and approval requirements, responsibilities, and timetable payment, assignment, and cancelation software requirements and updates documentation clinical and technical training acceptance testing (hospital facility and vendor) warranty, spare parts, and service and price protection. 

When managers want to cut costs they first look for supposedly nonessential activities or resources, such as training or excessive inventory of spare parts in the warehouse. Reducing expenditures on such activities and resources certainly leads to short-term cost reductions. However, over a longer period of time these cuts can create unsafe conditions. In Lessons from Longford Hopkins notes that cuts in the maintenance budget played a major role in that disaster. 

Spare Parts and the Four CS of Supply Chain Management... 

In many industries, the provision of spare parts and associated services represents a significant component of supply chain profits. Some studies [23] estimate US sales of spare parts and after-sales services to be 8% of the annual gross domestic product (GDP) or 1 trillion. Others [28] surest, for example, that in 2001, General Motors earned relatively more profits from its 9 billion in after-sales revenues than it did from 150 billion in car sales. Another estimate [124] suggests that the total cost of ownership of a product may far exceed the amount spent on the initial product purchase and may vary between five and twenty times the original product cost. The main conclusion from these studies is that managing spare parts supply chains and related services after a product is sold may have a significant impact on both primary demand as well as on profits. 

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