Maintenance Parts Management Excellence: A Holistic Anatomy

Description

Most successful organizations recognize Maintenance Parts and Procurement as a critical success factor to Asset Management Excellence and their fundamental supply chain value proposition. This book works as a guide to all the stakeholders that influence the success of their Maintenance Parts Operation and their enterprise’s bottom line. Maintenance Parts Management Excellence: A Holistic Anatomy defines the Maintenance Parts Managements role in Asset Management Excellence and expands on the importance of the Parts Inventory Planner role in an organization. It discusses how to create a unique Maintenance Parts Management Strategy for an organization and offers insights on the multiple strategies needed to create and maintain a Maintenance Parts inventory policy. The book also provides an organized overall approach to creating Maintenance Parts Management Excellence in an enterprise. Executives with an organization responsible for the construction, management, and disposal of all assets classes (plant, equipment, IT assets), consultants responsible for assignments associated with optimizing life cycle decisions for clients, maintenance, and reliability professionals within an organization, will benefit from this professional plus book. Upper-level undergraduate engineering students, as well as graduate students of management who focus on operations management and engineering graduate students addressing issues of maintenance and reliability engineering, may also be interested in this book. Cover Half Title Title Page Copyright Page Table of Contents Preface Acknowledgments About the Author References Chapter 1: Introduction: Why Maintenance Parts Management Is Important After-Product Sales Service Parts or Plant Maintenance Parts The Role of Maintenance Parts Management in Support of Asset Management Who Should Own Maintenance Parts Management? Benefits of Doing Maintenance Parts Management Well Who Are the Stakeholders for Maintenance Parts Management? Chapter 2: Maintenance Parts Excellence Influences Origins of the Maintenance Parts Excellence Pyramid The Maintenance Parts Management Community Influencers Starting a Maintenance Parts Excellence Culture Maintenance Parts Management Assessment Approach Design Principles and Design Points A Maintenance Parts Inventory Assessment Case Study Small Case Study Result Set Chapter 3: Maintenance Parts Strategy Development Maintenance Parts versus Production Warehousing Operations Productivity and Production Issues due to Poor Maintenance Parts Management Creating a Maintenance Parts Excellence Strategy Initiating a Maintenance Parts Strategy Development Program Executing the Maintenance Parts Program Strategy Initiatives A Design Thinking Approach Chapter 4: Organization Management in Maintenance Parts Organization Introduction Considerations for the Maintenance Parts Management Group Issuing: Issues, Delivery, Pick Lists Receiving and Storing: Receipts, Item Verification, Invoice Validation, and Item Storing Inventory Control, Locating, Counting, Tagging Audit and Analysis, Item Setup, Disbursement Analysis, Projects, Accuracy Control Health and Safety Considerations Setting Goals for the Maintenance Parts Management Group Organizational Considerations Maintenance Responsibilities in Managing Inventory Integrity Investing in Your Maintenance Parts Staff Process Management Disciplines in Maintenance Parts Case Study for Empowering Maintenance Parts Warehouse Staff Chapter 5: Change Enablement in Maintenance Parts Why Change Management Is Important Potential Reasons for Change Management in Maintenance Parts Management Understanding Change Scope and Business Case Four Pillars to Support Change Potential Project Risks in Change Performing Stakeholder Analysis People Readiness Change Lead Role/Task Examples Project Communications Considerations Training Considerations for Change Enablement Eight Critical Project Success Factors for a Change Lead Chapter 6: Key Performance Metrics for Maintenance Parts Excellence The Importance of KPIs Maintenance Parts Metric Complexities A High-Level Set of Maintenance Parts Functional Metrics A Balanced Scorecard for Maintenance Parts Management Business Dimension Levels and Value Driver Influences on Business Unit KPIs KPI Development Process Understanding Business Pain Points That May Need Measuring Converting Pain Points to Performance Indicators Managing Short- and Long-Term Goals Examples of Some of the Maintenance Parts Metrics Key Performance Indicators (KPIs) ( Table 6.6) Stock Room Metrics (PIs) ( Table 6.7) Source and Refurbishment (PIs) ( Table 6.8) Inventory Planning (PIs) ( Table 6.9) Chapter 7: Maintenance Parts Warehousing and Logistics Introduction to the Maintenance Parts Warehouse Flow Warehouse Setup Considerations Building Warehouse Space and Equipment Requirements Security, Safety, and Environmental Considerations in the Maintenance Parts Warehouse Security and Access Maintenance Parts Warehouse Tasks Organizational Requirements Inventory Integrity Management in the Maintenance Parts Warehouse Leveraging the 5S Discipline in Maintenance Parts Warehousing Automation and Technology in Maintenance Parts Warehousing Chapter 8: Sourcing and Refurbishing Parts Introduction to Procurement The Procurement Steps of a Parts Request Procurement Process Model Expanding on the Commodity Sourcing Activities Expanding on Supplier Relationship Management Activities Expanding on Transaction Execution Activities Leading Practices in Procurement The Role of Technology Can Contribute to Supporting Procurement Key Performance Metrics for Procurement Improving Procurement Processes Used Parts Returns and Parts Refurbishment Financial Benefits of Repairing Used Defective Parts and Returning to Stock Key Performance Metrics for UPR and Parts Repair Chapter 9: Inventory Planning and Policy Management Introduction to Inventory Planning Maintenance Parts Inventory Planning Inventory Policy Development Introducing Initial Spare Parts/Recommended Spare Parts Optimizer Date-Protected Parts Local Policy Override Parts Tactics Surplus Management in Stock Rooms Managing Automated Replenishment System Process Diagram for Inventory Policy Management ( Figure 9.5) Inventory Value Visibility Network Stock Location Echelon Levels Variables That Contribute to Inventory Policy Planning and Reporting Inventory Results Inventory Turns Inventory Carrying Costs Dealing with Inventory Obsolescence In Summary Chapter 10: Technologies Supporting Maintenance Parts Management Introduction to Maintenance Parts Management System Options Basic Inventory Management System Inventory Reservation Types Inventory Policy Management and Replenishment Algorithm Management Managing Rotating and Repairable Items in Inventory The Importance of Data Accuracy in Parts Management Item Parent–Child Relationship tracking Commodity Code and Condition Code Considerations Evolution of Maintenance Parts System Requirements Managing Tools in a Maintenance Parts Management System Inventory Integrity Management (Cycle Counting) Financial Tracking of Inventory Transactions in the Maintenance Parts Management System Automated Procurement Links to Suppliers Procurement Blockchain Capabilities Integrating Automated Storage and Retrieval Systems or Vertical Lift Machines into a Maintenance Parts System Chapter 11: Asset Lifecycle Alignment to Inventory Spare Parts Management Introduction to Asset Lifecycle The Design Engineer’s Role in Support of a Parts Inventory Strategy Asset Lifecycle Service Cycles by Asset Industry Asset Lifecycle Costing What Item Numbers Should Be in the Part System Initial Spare Parts A Maintenance and Operations Team’s Insights and Parts History Approach to ISP/RSP Development Creating an Initial Spare Parts List with the Help of OEM Data Initial Spare Parts Categorization Approach ( Figure 11.5) Creating an Initial Spare Parts List from an RCM Analysis Program Set of Data ISP/RSP Data Elements System Process Model for ISP/RSP Data Creation ( Figure 11.11) Chapter 12: Inventory Optimization Tactics in Spare Parts Management Introduction to Inventory Optimization Why Parts Are Stocked Inventory Policy Netting Managing Maintenance Parts Inventory by Asset Type Features and Elements of an Optimizer Tool Cost of Missed Parts Availability (Figure 12.6) Stakeholders of an Effective Parts Optimization Program Example (Case Study) The Cost of the Lost Maintenance Technician Time versus Inventory Costs (Case Study) Benchmarking Inventory and Service Levels (Case Study) Chapter 13: Preparing for Uber Change in Maintenance Parts Management Challenging the “Status Quo” in Maintenance Parts Management Classic Process Re-engineering Processes and Disciplines Assessing Current (As Is) Processes Analyzing the Current (As Is) Process and Developing the Future (To Be) Process Implementing the Process Improvement Initiatives (To Be) Process Examples of Re-thinking Maintenance Parts Management Excellence Chapter 14: Opportunities for Outsourcing in Maintenance Parts Management Introduction Third-Party Logistics Providers for Maintenance Parts Logistics Services Maintenance Parts Outsourcing Can Come in a Multitude of Types and Combinations Transportation Outsourcing Sourcing All Parts from a Supplier Maintenance Vehicle Outsourcing Outsourcing Warehouse Logistics Procurement Services Outsourcing Inventory Planning and Inventory Policy Outsourcing Highlight Inventory Holding and Purchasing Costs before and after a Stock Policy Reset Inventory Lifecycle Planning Outsourcing Chapter 15: Maintenance Parts Sales Introduction Strategy Directions for Aftermarket Parts Logistics Services A Parts Sales Case Study A Parts Sales Case Study (2) The Importance of OEM Parts Sales Chapter 16: An Anatomy of Maintenance Parts Management Excellence Introduction Elements of Leading Practices in Maintenance Parts Excellence Strategy Organization Systems and Data Support (Information Technology) Parts Sourcing and Refurbish Stores and Logistics Management Inventory Planning Key Performance Metrics and Benchmarking Asset Lifecycle Alignment Optimizing Inventory Re-thinking Maintenance Parts Processes for the Future Appendix A1: Maintenance Parts Excellence Questionnaire Instructions 1 Strategy 2 Organization 3 Information Technology – Systems Support 4 Source and Refurbish 5 Stores Logistics Management 6 Inventory Planning 7 Performance Metrics/Benchmarking 8 Asset Lifecycle Alignment 9 Optimizing Inventory 10 Re-thinking Parts Processes for the Future Permissions Appendix A2: Basic Inventory Planning Replenishment Logic Introduction Appendix A3: Reliability-Centered Maintenance Process Description For Example Index