The Lean Management of Spare Parts in Automotive Manufacturing

Dongdong Guo,Xingwu Yu,G Beydoun

doi:10.1051/matecconf/201821404005

Dongdong Guo, Xingwu Yu + Show 1 more

Open Access

https://doi.org/10.1051/matecconf/201821404005

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Abstract

Spare part management is one of the most important work for enterprises, especially for manufacturing enterprises; however, the spare part management problems trouble enterprise operators a lot. In this article, implementation methods of lean spare parts management are illuminated. Spare parts purchase process is declared to reduce the purchasing cost and inventory value. We had established a suitable lean spare parts inventory management model for consumable parts, wear parts, insurance parts and accident parts. In addition, methods of lean spare parts management had been created base on optimized supply chain, ERP and integrating repeated material inventory. We used SAP-iPro system and self-developed system to manage spare parts, so that warehouse management process, spare parts purchase process and maintenance process are standardized. According to theory analysis and practice, the remarkable economic benefit is created for enterprise by the means of optimizing spare parts distribution, standardizing and scientific spare parts management.

Highlights

A higher level for the normal operation of production equipment has been required in the field of automotive manufacturing with the increasingly severe competition in the global market
It has been identified that high cost of spare parts inventory has become the most troublesome problem in controlling the manufacturing production cost and production efficiency [2]
Under the policy of the company to implement the lean management, we have established a new lean spare parts management model shown in Figure 2, which is based on the supply chain, such as controlling the procurement process, improving the supplier's quality management methods, implementing the centralized procurement and some other specific measures combined with the experience of the other large scale manufacturing enterprises spare parts management

Summary

Introduction

A higher level for the normal operation of production equipment has been required in the field of automotive manufacturing with the increasingly severe competition in the global market. Implementing scientific management for spare parts in the aspects of procurement, delivery date, warehouse maintenance, inventory control, allocation and so on will play an important role in the equipment maintenance work. The surplus spare parts stock due to improper management will increase the operation cost of the enterprise. It has been identified that high cost of spare parts inventory has become the most troublesome problem in controlling the manufacturing production cost and production efficiency [2]. In order to ensure the scientific purchasing and reduce the stock funds effectively, more and more enterprises have realized that it is quite important to implement the lean management of spare parts. There is no doubt that the lean management mode will be imperative in the field of spare parts management

The overview of spare parts lean management

Research status of lean spare parts management

The model of lean spare parts Inventory management

Methods of lean spare parts management

Findings

Summary