Maintenance Parts Management Excellence: A Holistic Anatomy

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