Spare parts production

As a simplification for a design, an 80 to 85% utilization of the maximum possible mold life should be used. By way of example, this means that with a sales expectation of 800,000 components in the overall life cycle (start of series up to the end of the intended end of spare parts production), the mold should have a total output of about 1 million components. The difference of 200,000 components is a safety margin, which should prevent that an additional mold has to be manufactured at a... 

While you may not service your products, others may well do so and the standard requires that you collect information generated by the servicing organizations and convey it to those who can use it to improve the product and the manufacturing processes. This means that you will need to establish liaison links with servicing organizations and enlist their support in reporting to you any concerns they have about the serviceability or maintainability of the product, the availability of spare parts, and the usability of the manuals and other information you have provided. 

A survey of 500 plants that have implemented predictive maintenance methods indicates substantial improvements in reliability, availability and operating costs. The successful programs included in the survey include a cross-section of industries and provide an overview of the types of improvements that can be expected. Based on the survey results, major improvements can be achieved in maintenance costs, unscheduled machine failures, repair downtime, spare parts inventory, and both direct and in-direct overtime premiums. In addition, the survey indicated a dramatic improvement in machine life, production, operator safety, product quality and overall profitability. 

Assume that the new piece of production equipment is operating without incident for a year or more. The vendor used brand name parts for the piece of equipment but went bankrupt. All of a sudden, a key part on the equipment breaks. For some strange reason, facilities cannot figure out the part number. Unfortunately, there is no documentation because there was no IQ performed, which would normally detail the spare parts and of course part numbers and drawings. 

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]. 

Working capital. The working capital (WC) consists of feed and product inventories, cash for wages and materials, accounts receivable, and spare parts. A reasonable figure is the sum of these items for a 30-day period. 

As failures and breakdowns of these large rotary machines could lead to long and expensive repairs and to a corresponding loss of production it is advisable to keep the essential spare parts, for example, spare rotors, in stock. In older steam turbines, sometimes blade failures occurred, but this is no longer a problem due to improved blade design and shroud bands, which are standard today. 

Figure 122 shows an estimate of ammonia production costs at various locations. In this figure the capital-related costs are based on a debt/equity ratio of 60/40. With 6 % depreciation of fixed assets and spare material, 8 % interest on debts and 16 % ROI on equity, corresponding to a total of about 16.5 % of the total capital involved. The total capital includes the LSTK price for plant and storage, cost of the off-sites for an industrialized site, in-house project costs, spare parts and catalyst reserves, working capital. 

An indication of the kinds of improvisations both tolerated and required may be inferred from an astute case study of two East German factories before the Wall came down in 1989. Each factory was under great pressure to meet production quotas—on which their all-important bonuses depended—in spite of old machinery, inferior raw materials, and a lack of spare parts. Under these draconian conditions, two employees were indispensable to the firm, despite their modest place in the official hierarchy. One was the jack-of-all-trades who improvised short-term solutions to keep machinery running, to correct or disguise production flaws, and to make raw materials stretch further. The second was a wheeler-dealer who located and bought or bartered for spare parts, machinery, and raw material that could not be obtained through official channels in time. To facilitate the wheeler-dealer s... 

Inventories of raw materials, products, spare parts, and other supplies ... 

A program to ensure control of critical system documentation will be established. The files will be controlled by QA. Validation and centralized for easy retrieval. Equipment validation data such as operating and service manuals, purchase orders, manufacturer specifications, as-built drawings and schematics, spare parts lists, and any other information pertaining to the system will be included in the file. Separate validation files for Facility, Systems, and Process validation of each product, including all related data, will be maintained. Procedures will be developed to create files for new equipment, update information for existing equipment, control, removal, and return of information, etc. 

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. 

Original Equipment Manufacturer (OEM). Manufactures and sells finished products such as pumps, valves, compressors, vessels, etc., for which OEM s also supply spare parts. 

Excludes spare parts. h Includes farm, ranch, and forest products. e Includes fiber raw materials. 4 Includes industrial consumption. Includes aircraft, metals, military, petroleum, and adhesive. 

Although the robotics and furnaces employed in chemical demilitarization are unique, they are robustly designed and are expected to have adequate operating life if they are maintained and upgraded as needed. The designers and manufacturers of these components are continuing businesses that are available for support and spare and replacement parts production. 

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. 

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. 

Warehousing requires that raw materials, additives, spare parts, molds, tools, molded products, and so on be stored and handled safely and economically. Various systems are available to meet different needs in warehousing. They can handle schemes for integrating the inward and outward flow of goods, order picking and transportation, factory administration, and process control for warehousing tasks. 

By mid-1996, ERCOM Composite Recycling GmbH had mechanically recycled over 1 million SMC parts. Production scrap accounted for 750,000 parts and post consumer scraps 250,000 (from the Mercedes Recycling System MeRSy, BMW repair shops and Deutsche Telekom dismantling plants). As a result, over 2 million parts containing recyclate were put back into service in automobiles, including spare wheel well (Audi 320,000), noise barrier shield (VW 250,000), truck bumpers and front end panels (Mercedes Benz 600,000), sunroof frames (350,000), and other components (450,000). 

Environmental Increased production Increased productivity/efficiency Reduced energy consumption Reduced maintenance costs Reduced spare parts inventory Public relations... 

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