How to better manage spare parts?

The reserve of spare parts is generally reduced as much as possible, but there must be a certain safety reserve. I think you can determine it according to the condition of your equipment and the spare parts you consume daily. Specifically, the inventory management of equipment spare parts is a complicated and meticulous work and an important part of spare parts management. After the manufactured or purchased spare parts are put into storage, they should be properly preserved and carefully maintained in accordance with procedures and related systems to ensure the quality of spare parts inventory. Through the statistics and analysis of the dynamic information of spare parts distribution and use, we can find out the consumption law of spare parts in the process of use, gradually revise the reserve quota and reserve spare parts reasonably. At the same time, it also plays an important role in dealing with the backlog of spare parts in time and accelerating the capital turnover.

1. spare parts storage requirements

Spare parts in storage must be accepted one by one.

(1) spare parts in stock must meet the quantity, variety and specifications specified in the application plan and production plan;

(2) Check the qualification certificates of the warehousing parts, and conduct appropriate quality sampling inspection such as appearance;

③ The warehousing of spare parts must be completed by warehousing personnel and checked by the keeper;

Spare parts should be oiled and rustproof when put into storage. Spare parts should be registered in time, labeled (or card) and stored according to the purpose (user).

2. Spare parts storage requirements

(1) The warehousing spare parts shall be properly kept and maintained by the warehouse keeper, so as not to be lost, damaged, deformed or deteriorated, with clear accounts and neat patterns (Sanqing, Liang Qi, Sanhuan, No.4 positioning and No.5 pattern).

(2) Regularly refuel, store and check.

(3) Make regular inventory and report the dynamics of spare parts to relevant personnel at any time.

3. Spare parts distribution requirements

(1) Spare parts must be provided with a picking list. For different spare parts, corresponding methods and approval procedures should be formulated inside and outside the factory.

(2) Take out the spare parts and go through the corresponding financial procedures.

(3) After the spare parts are distributed, they shall be registered in time and the debit card shall be cancelled.

④ Spare parts with recycling value should be replaced with old ones, and corresponding management measures should be formulated.

4. Spare parts handling requirements

① Spare parts no longer needed by enterprises due to equipment transfer, modification, scrapping or other objective reasons shall be sold and disposed of in time as required;

(2) If spare parts are wasted due to drawings and technical errors or improper storage, it is necessary to find out the reasons, put forward preventive measures and treatment opinions, and report them to the competent leader for approval;

(3) Scrapping or transferring spare parts must be handled as required.

Calculation of spare parts reserve quota

Significance of calculation formula of spare parts reserve quota (1)

Which spare parts are often reserved depends on the service life of spare parts, and how much to reserve depends on the consumption of spare parts, the machine maintenance ability of enterprises and the supply cycle. When determining the spare parts reserve quota, we should take the principle of meeting the needs of equipment maintenance, ensuring production and not overstocking spare parts funds, and shortening the reserve period. Generally, it can be calculated by the following formula.

Because the service life (c) of parts is not easy to master, the actual consumption (m) is generally used instead.

Namely: m= e/ c

In this way, the above formula can be changed to: d=k? m？ z

Among them, the average service life of spare parts (C) refers to the average service life of a single spare part of the same kind from the beginning of use to the end of non-use, calculated in months. The calculation of C value needs to accumulate the actual consumption of spare parts and closely combine with the actual situation of the enterprise. Spare parts ownership (e) refers to the quantity of the same spare parts installed on all production equipment of the enterprise (not the inventory quantity).

The number of self-made spare parts = the number of the same self-made spare parts installed by a single device × the number of the same type of equipment.

Quantity of purchased spare parts = quantity of single equipment counted in equipment spare parts card or manual × quantity of equipment of the same type.

Spare parts consumption (m)-refers to the actual consumption of the same spare parts in a certain period, and the theoretical consumption can be replaced by the actual average consumption in an overhaul cycle.

Supply cycle (z)- For self-made spare parts, it refers to the time from application to finished product warehousing; For purchased spare parts, it refers to the time from application to arrival and warehousing.

Coefficient (k)-determined according to the equipment management and maintenance level, spare parts manufacturing capacity and manufacturing level, regional supply and cooperation conditions of the enterprise. Use decimals for good conditions and large numbers for poor conditions.

(2) Determine the maximum and minimum reserves and ordering points of self-made spare parts.

The minimum (low) spare parts reserve d min is the minimum reserve limit of spare parts, that is, the reserve limited by conditions in the spare parts supply cycle.

d min=k？ m？ z

The maximum (high) reserve (d max) is the maximum reserve limit of spare parts. It requires considering the most economical processing cycle and organizing the production batch economically and reasonably. Generally speaking, the maximum reserve should not exceed one and a half years' consumption.

d max=k？ m？ g

In the formula? M-monthly spare parts consumption;

Z- monthly spare parts supply cycle (manufacturing cycle);

G—— the most economical processing cycle calculated on a monthly basis (numbers such as 6, 8, 9, 10, 12 are generally selected). G usually refers to the most economical time from the first production of a spare part to the second production of the same spare part.

The most economical significance includes two aspects: reducing varieties and increasing batches in production; In order to reduce capital and speed up turnover, only by considering these two aspects can the most economical processing cycle be obtained.

K coefficient, generally between 1 and 1.5, depends on management, manufacturing, maintenance level, spare parts quality and regional cooperation.

(3) the determination of outsourcing spare parts reserve quota

The formula for calculating the reserve quota of purchased parts is d=k? m？ z

In the formula? D—— Reasonable reserve quota for purchasing spare parts;

M—— Average monthly consumption of purchased spare parts;

Z- supply cycle (annual order 12, semi-annual order 6, quarterly order 3, imported spare parts 24);

K coefficient (generally 1. 1~ 1.4).

All repairable and serviceable purchased spare parts shall be calculated according to the following formula

Reasonable reserve =m× repair period

3. Other factors that should be considered when determining the reserve quota of spare parts.

(1) Influence of changes in spare parts production and supply mode. With the gradual transformation of spare parts management from centralized production and centralized supply to marketization, the purchase quantity of spare parts will increase and the supply cycle will be shortened. Therefore, when determining the reserve quota, enterprises should determine the reasonable and economical reserve quota according to the supply situation and quality information of spare parts in the region and referring to the above formula.

② Influence of equipment continuity. For example, two or three shifts of production, the service life of spare parts is shorter than that of one shift of production 1.5~2 years.

(3) Spare parts for key equipment, spare parts that are difficult to purchase and special spare parts with ordering starting point can be appropriately increased.

Calculation formula of reserve quota

N=A？ k？ Answer? T/P

Where n is the reserve quota (piece);

A—— Number (sets) of similar equipment;

K—— the quantity (pieces) of similar spare parts for each equipment;

A- nonuniformity coefficient, which is determined by the product of a and k;

A.K 1？ 2 - 5 5 - 10 10 -20 20 -30

Answer? 1 0.9 0.8 ? 0.7 0.6

T—— spare parts manufacturing or ordering cycle (months) (factory processing is 6 months, outsourcing 12 months;

P—— Service life of spare parts (months).

In order to strengthen material management, standardize spare parts procurement, ensure normal supply of spare parts, control procurement costs and reduce production costs, this procurement regulation is formulated.

1 strictly abide by the company's material procurement management regulations.

2. The production or use department shall put forward the spare parts demand plan as required. The normal maintenance demand plan should be put forward 7 days in advance; The maintenance plan will be put forward within 30 days.

3. After the maintenance demand plan is reviewed by the production department or the technical department, it is submitted to the vice president in charge of production for approval.

4. The temporary demand plan is put forward by the workshop or the user department and reviewed by the production management department.

5 Put forward the demand plan. The workshop or department office will report the audited demand plan to the vice president in charge of supply for approval, and then submit it to the supply department, which is responsible for purchasing.

The supply department adheres to the procurement principle of multi-party inquiry, shopping around and selecting the best and purchasing spare parts at a fixed point.

7. Foreign spare parts or spare parts with high technical requirements need to be jointly purchased by technical departments. (Due to the long procurement cycle of foreign spare parts, it is necessary to purchase them in advance)

After purchasing spare parts, you should ask for invoices and go through warehousing procedures in time according to financial regulations. Go to the financial department to handle the settlement and suspense procedures in time.

In the spirit of reducing the maintenance cost of the company and strengthening the planned management, according to the arrangement of the team and personnel of Hankou Power Supply Company, the spare parts of the company are now available