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