Spare Parts - What Do Bakers Want

Transcript

1. Spare Parts
   “What Do Bakers Want?”
   

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2. Unexpected Downtime
   More costly than you think. An industry sampling…
   1 Hour Of Unexpected Production Line Downtime
   $0
   $2
   $4
   $6
   $8
   $10
   $12
   Baker "A" Baker "B" Baker "C" Baker "D" Baker "E"
   Cost ($1,000's)
   Labor
   Cost Variance
   Transportation
   Materials
   Avg costs are shown. Actual costs are situational & depend on many variables, such as proximity of alternative sourcing and line crewing.
   Excludes sales & customer account costs, which could be significant and long-term.
   1 Hour Of Unexpected Production Line Downtime
   $0
   $2,000
   $4,000
   $6,000
   $8,000
   $10,000
   $12,000
   Baker "A" Baker "B" Baker "C" Baker "D" Baker "E"
   Cost/Hr Unexpected Downtime
   Labor
   Cost Variance
   Transportation
   Materials
   

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3. • Manufacturer’s (Sub-supplier’s) part numbers
   o Electrical, such as starters, drives & PLC’s
   o Mechanical, such as bearings, sprockets, bushings, seals, & o-rings
   o Domestic part equivalents if internationally supplied
   • Group by importance to operation
   o High / On site
   o Medium / Suggested
   o Low / Available Locally
   • Typical stock level from the equipment manufacturer
   o In-stock part? Special order, with lead time?
   • Volume discount availability
   o Wear-parts, for example, may be a volume purchase
   The Spare Parts List
   Informative content is key.
   

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4. The Spare Parts List
   Information – Organized/Comprehensive
   

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5. The Spare Parts List
   Information – Organized/Comprehensive
   

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6. The Spare Parts List
   Information – Organized/Comprehensive
   

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7. A Recommended Flow Chart
   Early collaboration provides for the reduction of risk.
   Supplier Issues
   “Edited”
   Recommended
   Spare Parts List
   Baker Checks
   • Bakery Inventory For Duplicates
   • Alternative Pricing/Sourcing
   Baker Orders
   Spare Parts
   Supplier
   Procures & Ships
   Parts
   Baker Inventories Parts, Enters
   PM’s into Systems if applicable
   Equipment In-Service
   Parts On-Hand
   Supplier Issues
   Prelim Spare
   Parts List with
   Proposal
   Supplier
   Completes Equip
   Engineering &
   Design
   2 - 6 weeks
   TurnWaround
   Onsite 2 Weeks
   Prior to Startup
   

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8. • Begin warranty at time of startup, not purchase
   • Provide revision bulletins and part upgrade notices
   • Part life cycle estimates for future predictive maintenance
   • Spare parts inventory audits by OEM’s
   • Know & understand each customer’s standard specifications
   o Local bakeries may elude corporate oversight
   The Spare Parts List
   Other value-added features for bakers.
   

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9. • Consignment
   • Spares for startup only, returned if not used
   • Regional Inventories
   o Shared Parts
   • Web-based Spend Management Solutions, i.e. Ariba
   • Web-based part reference, exploded assembly views
   • On-site Managed Storerooms
   • Forecasting & Planning Solutions, i.e. SAP
   o Predictive ordering
   o Built into control logic
   o Assignable life cycles, i.e. order @ 80% of part life for critical parts
   Alternative Approaches
   Proven to be effective in reducing costs & risk.
   

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10. The Asset Healthcare Triangle
    SAM – Strategic Asset Management
    

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11. Supplier/Baker Relationship
    • Bakers need your help to combat the infant mortality of
    components and the random losses of machine parts, which are
    the leading failure mode affecting equipment reliability.
    • Often these losses are caused by human intervention through time
    based “Preventive Maintenance” tasks and the simple act of
    production cycles.
    • We must move from reactionary maintenance to predictive
    maintenance (part life cycles) and meantime between failure
    analysis.
    • The total cost for carrying an item in inventory may be as high as
    30 – 40% of the value of the item per year.
    • Predictive Maintenance saves everyone money.
    The Asset Healthcare Triangle
    SAM – Strategic Asset Management
    

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12. ReliabilityWeb.com
    

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13. MRO-zone.com
    

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14. Resources
    

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15. Spare Parts
    “From the Baker’s point of view”
    Q & A
    

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