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1 – 10 of over 2000
Article
Publication date: 4 November 2020

Leandro Reis Muniz, Samuel Vieira Conceição, Lásara Fabrícia Rodrigues, João Flávio de Freitas Almeida and Tãssia Bolotari Affonso

The purpose of this paper is to present a new hybrid approach based on criticality analysis and optimisation to deal with spare parts inventory management in the initial…

1511

Abstract

Purpose

The purpose of this paper is to present a new hybrid approach based on criticality analysis and optimisation to deal with spare parts inventory management in the initial provisioning phase in the mining industry. Spare parts represent a significant part of mining companies' expenditures, so it is important to develop new approaches to reduce the total inventory value of these items.

Design/methodology/approach

This hybrid approach combines qualitative and quantitative methods based on VED (vital, essential and desirable) analysis, analytical hierarchical process (AHP), and e-constraint optimisation method to obtain the spare parts to be stocked. The study was applied to a large mining company. The mineral sector was chosen due to the great importance to the emerging Brazilian economy and the lack of researches in this sector. In addition, the spare parts have a relevant weight on the total inventory cost.

Findings

Present a novel approach combining multi-objective optimisation and multi-criteria evaluation approaches to tackle the inventory decision in spare parts management. This work also defines and classifies relevant criteria for spare parts management in the mineral sector validated by specialists. The proposed approach achieves an average increase of 20.2% in the criticality and 16.6% in the number of items to be stocked compared to the historical data of the surveyed company.

Research limitations/implications

This paper applies the proposed approach to a mining company in Brazil. Future research in other companies or regions should analyse the adequacy of the criticality criteria, hierarchy and weights adopted in this paper.

Practical implications

The proposed approach is useful for mining industries that deal with a large variety of resource constraints as it helps in formulating appropriate spare part strategies to rationalise financial resources at both tactical and strategic levels.

Originality/value

The paper presents a new hybrid method combining the AHP a multi-criteria decision making (MCDM) approach coupled with e-constraint optimisation to deal with spare parts inventory management allowing for a better spare parts inventory analysis in the initial provisioning phase and providing managers with a systematic tool to analyse the trade-off between spare parts criticality and total inventory value.

Details

The International Journal of Logistics Management, vol. 32 no. 1
Type: Research Article
ISSN: 0957-4093

Keywords

Article
Publication date: 26 December 2023

Jesus Vazquez Hernandez and Monica Daniela Elizondo Rojas

To redesign the spare parts (MRO) inventory management at Company XYZ's warehouse, considering the conditions after the COVID-19 pandemic.

Abstract

Purpose

To redesign the spare parts (MRO) inventory management at Company XYZ's warehouse, considering the conditions after the COVID-19 pandemic.

Design/methodology/approach

To address this research project, the authors integrated three methodologies: action research, Lean Six Sigma (DMAIC) and Cross Industry Standard Process for Data Mining. These methodologies integrated the Lean Six Sigma (LSS) 4.0 framework applied in this project.

Findings

The spare parts inventory value was reduced by 15%, and inventory turnover increased by 120% without negatively impacting the internal service level.

Practical implications

Practitioners leading or participating in continuous improvement projects (CIPs) should consider data quality (data available and data trustworthiness), problem-solving approach and target area involvement to achieve CIP goals. Otherwise, the LSS 4.0 could fail or extend its duration by several weeks or months.

Originality/value

This project shows the importance of controlling a target area before deciding to conduct a LSS 4.0 project. To address this problem, the LSS 4.0 team implemented 5S during the measure phase of the DMAIC. Also, this project offers significant practitioner and theoretical contributions to the body of knowledge about LSS 4.0.

Details

The TQM Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 12 October 2015

S. P. Sarmah and U. C. Moharana

The purpose of this paper is to present a fuzzy-rule-based model to classify spare parts inventories considering multiple criteria for better management of maintenance activities…

1566

Abstract

Purpose

The purpose of this paper is to present a fuzzy-rule-based model to classify spare parts inventories considering multiple criteria for better management of maintenance activities to overcome production down situation.

Design/methodology/approach

Fuzzy-rule-based approach for multi-criteria decision making is used to classify the spare parts inventories. Total cost is computed for each group considering suitable inventory policies and compared with other existing models.

Findings

Fuzzy-rule-based multi-criteria classification model provides better results as compared to aggregate scoring and traditional ABC classification. This model offers the flexibility for inventory management experts to provide their subjective inputs.

Practical implications

The web-based model developed in this paper can be implemented in various industries such as manufacturing, chemical plants, and mining, etc., which deal with large number of spares. This method classifies the spares into three categories A, B and C considering multiple criteria and relationships among those criteria. The framework is flexible enough to add additional criteria and to modify fuzzy-rule-base at any point of time by the decision makers. This model can be easily integrated to any customized Enterprise Resource Planning applications.

Originality/value

The value of this paper is in applying Fuzzy-rule-based approach for Multi-criteria Inventory Classification of spare parts. This rule-based approach considering multiple criteria is not very common in classification of spare parts inventories. Total cost comparison is made to compare the performance of proposed model with the traditional classifications and the result shows that proposed fuzzy-rule-based classification approach performs better than the traditional ABC and gives almost the same cost as aggregate scoring model. Hence, this method is valid and adds a new value to spare parts classification for better management decisions.

Details

Journal of Quality in Maintenance Engineering, vol. 21 no. 4
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 10 August 2012

Jakiul Hassan, Faisal Khan and Mainul Hasan

Purpose – The purpose of this paper is to propose a risk‐based approach for spare parts demand forecast and spare parts inventory management for effective allocation of limited…

1866

Abstract

Purpose – The purpose of this paper is to propose a risk‐based approach for spare parts demand forecast and spare parts inventory management for effective allocation of limited resources. Design/methodology/approach – To meet the availability target and to reduce downtime, process facilities usually maintain inventory of spare parts. The maintaining of non‐optimized spare parts inventory claims more idle investment. Even if it is optimized, lack of attention towards the critical equipment spares could threaten the availability of the plant. This paper deals with the various facets of spare parts inventory management, mainly risk‐based spare parts criticality ranking, forecasting, and effective risk reduction through strategic procurement policy to ensure spare parts availability. A risk‐based approach is presented that helps managing spare parts requirement effectively considering the criticality of the components. It also helps ensuring the adequacy of spare parts inventory on the basis of equipment criticality and dormant failure without compromising the overall availability of the plant. Findings – The paper proposes a risk‐based approach that used conjugate distribution technique with the capability to incorporate historical failure rate as well as expert judgment to estimate the future spare demand through posterior demand distribution. The approach continuously updates the prior distribution with most recent observation to give posterior demand distribution. Hence the approach is unique in its kind. Practical implications – Appropriate spare parts unavailability could have great impact on process operation and result in costly downtime of the plant. Following proposed approach the availability target can be achieved in process industry having limited maintenance resources, by forecasting spare parts demand precisely and maintaining inventory in good condition. Originality/value – Adopting the approach proposed in the paper, risk level can be minimized and plant availability can be maximized within the financial constraint. The resources are allocated to the most critical components and thereby increased availability, and reduce risk.

Details

Journal of Quality in Maintenance Engineering, vol. 18 no. 3
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 11 April 2018

Abhijeet Ghadge, Georgia Karantoni, Atanu Chaudhuri and Aravindan Srinivasan

The purpose of this paper is to assess the impact of additive manufacturing (AM) implementation on aircraft supply chain (SC) networks. Additive and conventional manufacturing…

3366

Abstract

Purpose

The purpose of this paper is to assess the impact of additive manufacturing (AM) implementation on aircraft supply chain (SC) networks. Additive and conventional manufacturing spare part inventory control systems are studied and compared, revealing insights into SC performance.

Design/methodology/approach

A leading global commercial airline’s SC network data are used to model the research problem. A system dynamics simulation approach is followed, drawing out insights for managers.

Findings

A significant improvement in SC efficiency is observed through the implementation of AM, rendering it a worthwhile investment for global SCs. AM helps to balance inventory levels, and increase responsiveness while decreasing disruptions and carbon emissions in the supply networks.

Practical implications

The paper offers guidance on the adaption of AM in aircraft SCs and AM’s impact on spare part inventory systems.

Originality/value

The study provides robust evidence for making critical managerial decisions on SC re-design driven by a new and disruptive technology. Next-generation SC and logistics will replace the current demand for fulfilling material products by AM machines.

Details

Journal of Manufacturing Technology Management, vol. 29 no. 5
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 8 May 2017

Meimei Zheng and Kan Wu

The purpose of this paper is to propose a smart spare parts inventory management system for a semiconductor manufacturing company.

1710

Abstract

Purpose

The purpose of this paper is to propose a smart spare parts inventory management system for a semiconductor manufacturing company.

Design/methodology/approach

With the development of the Internet of Things and big data analytics, more information can be obtained and shared between fabs and suppliers.

Findings

On the basis of the characteristics of spare parts, the authors classify the spare parts into two types, the consumable and contingent parts, and manage them through a cyber-physical inventory management system.

Originality/value

In this new business model, the real time information from machines, shop floors, spare parts database and suppliers are used to make better decisions and establish transparency and flexibility between fabs and suppliers.

Details

Industrial Management & Data Systems, vol. 117 no. 4
Type: Research Article
ISSN: 0263-5577

Keywords

Article
Publication date: 1 March 2004

Marcello Braglia, Andrea Grassi and Roberto Montanari

Inventory constraints, costs of lost production, safety and environmental objectives, strategies of maintenance adopted, logistics aspects of spare parts are some of the criteria…

9377

Abstract

Inventory constraints, costs of lost production, safety and environmental objectives, strategies of maintenance adopted, logistics aspects of spare parts are some of the criteria taken into account, and spare parts classification is thus defined with respect to multiple attributes. In virtue of the large number of the potential operational characteristics to be considered, the decision diagram is integrated with a set of analytic hierarchy process models used to solve the various multi‐attribute decision sub‐problems at the different levels/nodes of the decision tree. An inventory policy matrix is defined to link the different classes of spare parts with the possible inventory management policies so as to identify the “best” control strategy for the spare stocks. The principles of the theory and an actual application in a company operating in the paper industry are reported in the paper.

Details

Journal of Quality in Maintenance Engineering, vol. 10 no. 1
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 9 October 2017

Jouni Kauremaa and Jan Holmström

The purpose of this paper is to study the adoption and motivation to adopt global spare parts practices in autonomous units servicing the products of an original equipment…

Abstract

Purpose

The purpose of this paper is to study the adoption and motivation to adopt global spare parts practices in autonomous units servicing the products of an original equipment manufacturer.

Design/methodology/approach

The methodological approach is case study investigating the reasons for different levels of use and the perceptions regarding the benefits of a centralized supply chain management in four representative service units.

Findings

Autonomous spare part units often source locally because local suppliers are easy to work with in terms of purchasing processes and have no requirements for systematic planning and control of spare parts purchases and inventory management. However, increasing the share of centrally sourced and managed spare parts in the supply chain brings advantages in terms of lower total cost and higher availability. From the perspective of individual subunits engaged in providing product support services, this advantage of relying on a centrally managed spare parts supply chain of an original equipment manufacturer is not self-evident. Autonomous units frequently choose to continue sourcing spare parts from alternative sources, undermining the economies of scale attainable through the original equipment manufacturer’s supply chain. Higher levels of use are facilitated by back-office purchasing management at the unit level. The positive perceptions of centralized supply management in general – including the relationship between the supply unit and the service unit – further facilitate adoption, while local requirements and practices inhibit it.

Research limitations/implications

The study is a single case study and presents proposals requiring further study of the reasons for the observed differences in use of centralized supply chain management.

Practical implications

Centralized spare parts management service requires investment in back-office resources at the service unit level.

Originality/value

The research increases the practical relevance of existing research through an empirical investigation on the autonomous units’ motivations for and perceived benefits of centralized spare parts supply.

Details

Journal of Quality in Maintenance Engineering, vol. 23 no. 4
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 4 January 2024

Nishant Kulshrestha, Saurabh Agrawal and Deep Shree

Spare Parts Management (SPM) and Industry 4.0 has proven their importance. However, employment of Industry 4.0 solutions for SPM is at emerging stage. To address the issue, this…

Abstract

Purpose

Spare Parts Management (SPM) and Industry 4.0 has proven their importance. However, employment of Industry 4.0 solutions for SPM is at emerging stage. To address the issue, this article is aimed toward a systematic literature review on SPM in Industry 4.0 era and identification of research gaps in the field with prospects.

Design/methodology/approach

Research articles were reviewed and analyzed through a content-based analysis using four step process model. The proposed framework consists of five categories such as Inventory Management, Types of Spares, Circularity based on 6Rs, Performance Indicators and Strategic and Operational. Based on these categories, a total of 118 research articles published between 1998 and 2022 were reviewed.

Findings

The technological solutions of Industry 4.0 concepts have provided numerous opportunities for SPM. Industry 4.0 hi-tech solutions can enhance agility, operational efficiency, quality of product and service, customer satisfaction, sustainability and profitability.

Research limitations/implications

The review of articles provides an integrated framework which recognizes implementation issues and challenges in the field. The proposed framework will support academia and practitioners toward implementation of technological solutions of Industry 4.0 in SPM. Implementation of Industry 4.0 in SPM may help in improving the triple bottom line aspect of sustainability which can make significant contribution to academia, practitioners and society.

Originality/value

The examination uncovered a scarcity of research in the intersection of SPM and Industry 4.0 concepts, suggesting a significant opportunity for additional investigative efforts.

Details

Journal of Quality in Maintenance Engineering, vol. 30 no. 1
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 20 December 2022

Som Sekhar Bhattacharyya, Onkar Kulkarni and Ashutosh Mishra

The purpose of this research was to study the impacts of adoption of additive manufacturing (AM) for spare parts procurement, specifically in the context of supply chain…

Abstract

Purpose

The purpose of this research was to study the impacts of adoption of additive manufacturing (AM) for spare parts procurement, specifically in the context of supply chain resilience (SCR) especially regarding efficient spare parts inventory management. Furthermore, key narratives in the adoption of AM toward better SCR are explored.

Design/methodology/approach

In-depth interviews with semi-structured open-ended questionnaire were conducted to collect primary qualitative data from 24 supply chain management (SCM) experts. Respondents consisted of experts across various industries. The data were analyzed by thematic content analysis method.

Findings

The results indicated that AM could be a suitable tool to reduce dependence on original equipment manufacturers (OEMs) for spare parts procurement. Data analysis also revealed that AM adoption might lead to significant cost and lead time reduction. Designs protected as intellectual properties (IP), substantive post-processing requirements and material compatibility were revealed to be barriers in adoption.

Research limitations/implications

The impacts of utilizing AM for procurement of spare parts on the overall resilience of the supply chain were highlighted. Theoretical analysis of the findings was based on theoretical aspects of SCR. This was especially regarding efficient spare parts inventory management. The study results revealed the factors responsible adoption of the AM technology. A novel approach was undertaken to study the effect of AM adoption on “time-to-market” of newly launched products.

Practical implications

The research provided insights regarding practical applications of AM adoption in spare parts procurement. The study could be beneficial to the early adopters of AM across industries for making managerial decisions. Unfamiliarity of supply chain managers with the AM technology was believed to be a major reason to adopt the technology. The study provided essential inputs regarding challenges and alternate adoption strategies of AM. Thus, the research was believed to be of potential value for creating awareness among supply chain managers regarding AM technology.

Originality/value

The research provided new insights on the impact of AM adoption in the context of SCR toward efficient spare parts inventory management. Various limiting and facilitating factors specific to Indian context were also explored.

Details

Benchmarking: An International Journal, vol. 30 no. 10
Type: Research Article
ISSN: 1463-5771

Keywords

1 – 10 of over 2000