Control Of Spare Parts Research Articles

Joint Optimization of Spare Part Supply and Opportunistic Condition-Based Maintenance for Onshore Wind Farms Considering Maintenance Route

Maintenance and inventory control of spare parts are of great importance for efficiently managing onshore wind farms. Considering the economic and graphical dependencies among wind turbines and the stochastic degradations of the components in the turbines, this article studies the joint optimization of opportunistic condition-based maintenance and spare parts supply for onshore wind farms to minimize the operation and maintenance cost rate. For each field maintenance, the specific turbines, with failed components, are selected for replacement using a clustering method, and the shortest route for visiting the turbines with failed components is scheduled. The maintenance team departs from a maintenance center with spare parts, maintains the selected turbines with failed or degraded components, and then returns to the center. This complicated and practical problem has never been considered as a whole in the literature. An optimization model is established, and a simulation-based approach is developed to solve it. A special case, for which a solution can be obtained by directly solving a nonlinear programming model, is provided to verify the results obtained by the simulation-based approach. Examples for various scales of wind farms are provided, and an analysis is performed for determining the length of a recommended maintenance interval.

ANALYSIS FOR PHYSICAL ERGONOMIC FACTORS IN OIL TANKER CASE STUDY

Over the next five years, shipping industry is predicted to grow at a 3.4% annual rate. However, marine accidents are on the rise, threatening both safety and expenses. Marine accidents happen for a variety of causes, including ergonomic issues, ergonomics is the study of how individuals interact with other components of a system, and it employs theory, concepts, data, and approaches to optimize human well-being and overall system performance. This paper aimed to assess physical ergonomic elements and reviewed the previous studies related to ergonomic factors, particularly those related to the marine industry; furthermore, a variety of physical ergonomic factors were selected to be evaluated in a tanker ship as case study. Using statistical analysis to assess physical ergonomic elements in other merchant ships and to compare the results to case study result for finding out the level of similarity, it was discovered that the majority of physical ergonomic factors were unsatisfactory, including severe consequences as a result of poor workplace design such as inadequate lighting, extreme temperature and noise. KEYWORDS: Maritime transport, Marine accidents, Physical ergonomic factors, Lighting, Noise, Inclined ladder, Spare parts control.

Reversing Negative Trends in Spare Parts Control

The consumer SPARE BROTHERS’ a Colombo, Sri Lanka company, commissioned the implementation of the online e-commerce management system. The users currently manage its employees' significant amounts of data manually using a manual approach. The suggested solution enables consumers to store and manage data in own database, greatly improving the efficiency of their data handling methods. The suggest system is designed to handle all the steps involved in managing a spare parts business, including consumer, store, cart, payment, delivery, order, and rider management. Firstly, if a user is already a consumer, user can connect to the system with users’ credentials and be redirected to user’s responsible side. If not, user can sign up for the system. Here, it includes with this system set up as a distinct site for the user and the administrator. The system's spare parts can be added by the admin, and those parts will then appear on the user side. Hence that consumer can purchase products based on user’s interests. Users can manage cart items here, and if user’s wish to proceed to check out, users can enter own payment and delivery details. After the order is complete, the administrator can designate a rider to transport those things to the appropriate location. Lastly, the admin can edit, delete, and generate certain essential reports to manage all the user, product, order, delivery, and rider details. Consequently, the administrator can add notifications, search relevant categories, and allow users to add wish lists. The solution decreases data manipulation errors in the present process, leading to a significant improvement in the utilization of human resources. It enhances consumers' interactions with their customers, increasing revenue for the company. The process is simple to use, dependable, and effective, and its statistics meet the needs of consumers.

Control of External Tire Spare Parts 7.50-16 Inefficiency Inventory Costs Based on Economic Order Quantity

This study focuses on inventory control of spare parts outside the prohibition 7.50-16 to streamline inventory costs. The method used is Economic Order Quantity with the type of case study design at the company PT. XYZ with the object of research is the supply of Outer Tire Parts 7.50-16. In data collection, the researcher compares the Traditional or Actual Company Method with the Economic Order Quantity Method in 2019 and 2020. The data that has been collected becomes several references in the calculation so that there is a difference between the two methods. The results show that the Economic Order Quantity method can streamline inventory control beyond 7.50-16 at PT. XYZ.

Quality assurance of control at machine-building enterprises of repair profile

The quality of repair of the units is significantly influenced by many factors, and this is not only the wear and tear of the parts coming for repair, the low qualification of the personnel, the old technological equipment, but also the poorly functioning system for organizing metrological support for production, from where there is a significant impact of the error of the measurement tools used on the conclusion of the validity of the parts. It is proposed to select control means not only according to the requirements of regulatory documentation, but also taking into account the impact of losses from measurement error. Dependence is given to estimate the economic effect of the replaced measuring instruments by more accurate ones. Using the example of crankshaft neck control under repair production conditions, it is shown that the use of universal measuring instruments with a lower error significantly reduces the level of losses from incorrect rejection and acceptance of critical parts. Features of incoming control of spare parts are disclosed and the feasibility of using only original parts of the manufacturer is justified.

Оценка целесообразности организации входного контроля качества запасных частей в условиях автотранспортного предприятия

The efficiency of vehicle operation largely depends on the quality of the spare parts used in the maintenance and repair of vehicles. The significance of the factor under consideration is determined by the complex influence on the economic indicators of vehicle operation and on traffic safety indicators. One of the measures aimed at improving the efficiency of operation is the organization of input quality control of spare parts. The costs of conducting and technological complexity of the input control vary significantly for different controlled objects, the effect of its implementation is ambiguous, which determines the relevance of the task of evaluating the effectiveness and expediency of its organization. Based on the urgency of the problem, the aim of the study is to improve the efficiency of the operation of motor vehicles by determining the optimal parameters of the input quality control system for spare parts. The hypothesis is put forward that the introduction of quality control of spare parts in the production cycle of motor transport and service enterprises will increase the efficiency of vehicle operation. To achieve this goal, a mathematical model for evaluating the effectiveness of input quality control of spare parts has been developed. Based on the parameters of the developed model, the target function of the study is de-termined, and restrictions due to the operating conditions of vehicles are established. Based on the results of the analysis of the assessment of the significance of factors that determine the efficiency of transport activities, it is proposed to use the value of total costs, including the likely damage from missing a defective part, unit, or unit, as the main criterion for the effectiveness of input quality control of spare parts . On the basis of the created mathematical model, a methodology for evaluating the feasibility of organizing input quality control of spare parts used in the maintenance and repair of vehicles is developed To confirm the proposed hypothesis, the adequacy of the developed model was checked. One of the largest passenger motor transport enterprises of the city of Orenburg — CJSC «Avtokolonna 1825» was chosen as the base for the study. As a model unit, the gimbal transmission of buses of the KaVZ family is considered. It is established that the direct costs of organizing the input control of this node are compensated by the savings due to the increased reliability of vehicles. But, based on the fact that this reduces the likelihood of road accidents caused by the failure of the cardan transmission, conclusions are drawn about the feasibility of organizing input control.

Possibilities of 3D scanning of parts during repair of agricultural machinery

New high-precision and productive tools are needed due to the increasing requirements to the finishing accuracy of reworked parts and the assembly of units and machines in repair production. One of the most dynamically developing areas of digital production is the use of 3D technologies. They are most actively used in the aviation and automotive industry, as well as in the manufacture of machine elements from various parts. In recent years, there have been some publications on the use of 3D technologies in the repair of machines, including the reconditioning and hardening of parts. The current global trend is the creation of digital measurements and systems for contactless optical quality control of products. The paper and analyzes 3D scanning technologies developed by scientific and educational organizations, as well as presented at various international specialized exhibitions. The analysis and synthesis of information revealed that various laser scanners have been developed and used for 3D scanning, mainly for manufacturing quality control. The study analyzes the possibilities of their use to monitor the geometric parameters of parts of agric ultural machines during the input control of spare parts and repair of machines. 3D scanning has been found to improve measurement accuracy and performance compared to contact tools. The paper presents the main directions of 3D technologies in repair production. A promising area of introducing 3D technologies into repair production is the integrated use of additive technologies and 3D scanning. In case of fault detection using a 3D scanner, the wear value is determined, and the 3D printer recovers the wornout surface taking into account the non-uniformity of wear. Thus, the additive material consumption is reduced from 20 to 90%.

Decreasing Total Inventory Cost by Controlling Inventory in Motorcycle Dealer

This research was conducted at one of the motorcycle dealers in Indonesia. Besides selling motorcycles, this dealer also provides services to repair motorcycles and sells genuine motorcycle parts. Inventory management which the company carried out is still not good enough because there are still demand for spare parts from consumers that cannot be fulfilled by the company. The purpose of this study is to draw up a plan to control spare parts by paying attention to the spare parts that need to be considered, estimating the exact number of spare parts demand, knowing the smallest total inventory cost, knowing the amount of safety stock needed, and knowing when to reorder. In preparing the spare parts control, the methods used are ABC analysis, demand forecasting method, and EOQ method. The results of this study are plans to control the inventory of Tire, Rr. such as the forecasting sales of Tire, Rr. as many as 17338, economic order quantity of Tire Rr are 2158 units, the number of safety stocks of Tire, Rr. needed in 2020 are 1738 units, and the reorder point in 2020 is 8 times with the total inventory cost for Tire, Rr. in 2020 is Rp. 30,009,005.

A Probabilistic Modeling of the Demand and Supply for Rotable Aircraft Components (Case Study: Brake Assembly of Boeing 737-800)

Spare parts control is an important factor in every airlines company. The unavailability of the spare parts may affect the airlines operationally, thus a delay and even a cancellation may happen. A common assumption used to calculate spare part requirements is that the demand is stochastic and the supply is constant. But in real operational circumstance, both of those are stochastic. This research develops the spare parts demand and supply model, and the calculation method of service level and safety stock in the bi-variate distribution from a real data of demand and supply of a rotable component. A fit test is conducted to determine the probability density function of the distribution. An analysis is then carried out after implementing the model in a case study. Historical data of brake assembly used in Boeing 737-800 New Generation is used in the case study. The result of this research are a model to determine demand and supply of aircraft spare part components, a method to calculate service level and safety stock for probabilistic model of demand and supply, and the amount of spare parts required for a brake assembly inventory system

Possibilities of 3D-scanning technologies in the repair of agricultural and forestry equipment

The share of the main types of agricultural machinery with a service life of more than 10 years in the total volume of equipment remains high. The maintenance the performance of machinery and equipment are performed mainly by repair and restoration processes. In recent years, there used a 3D-scanning technology in the repair of machines. (Research purpose) The research purpose is in searching for the possibility of using 3D-scanning technologies in the repair of equipment based on the analysis of information materials. (Materials and methods) Authors used open information sources from various scientific and educational organizations for analysis. The great attention has been paid to the analysis of 3D-scanning technologies presented at various international specialized exhibitions. It was found that various laser scanners have been developed and used for 3D-scanning, mainly for quality control of parts manufacturing. It was also found that they can be used to control the geometric, physical and mechanical parameters of agricultural machinery parts during the input control of spare parts and repair of machines. (Results and discussion) It has been found that 3D-scanning improves the accuracy and performance of measurements in comparison with contact devices. The article notes that the use of 3D-scanning in convergent modeling technologies and in additive manufacturing is becoming a modern trend in mechanical engineering. (Conclusions) A promising direction for the introduction of 3D-technologies in repair production is the integrated use of additive technologies and 3D-scanning; when parts are defective after disassembly of the repaired units, the machine uses a 3D-scanner to determine the wear, and a 3D-printer to restore the worn surface, taking into account the uneven wear. The advantages of this repair technology include increasing the accuracy of measurement, reducing the range of measurement tools used, and the ability to restore parts of complex geometric shapes. Spot application of a layer of additive material to the wear site reduces material consumption by 20-90 percent.

Use of contactless methods and means for checking the quality of agricultural machinery spare parts

Quality control of spare parts of agricultural machinery has now acquired significant relevance, which is due to the presence of a large share of low-quality products on the market. The use of low-quality spare parts increases the risk of failure of the equipment in use, which lead to its downtime and financial losses of the agricultural producer, which is highly undesirable in the modern realities of the domestic agricultural industry. Contactless methods and tools for quality control of spare parts will improve the accuracy and productivity of control. (Research purpose) The research purpose is in developing a device that allows to control the geometric, physical and mechanical parameters of spare parts, the use of which should increase the performance and accuracy of control due to a comprehensive non-contact method of measuring spare parts. (Materials and methods) Authors applied a non-contact triangulation method for controlling geometric parameters and a X-ray fluorescence method for controlling physical and mechanical parameters. (Results and discussion) The article presents the devices that are closest in technical parameters and based on them an automated measuring device using methods and means that allows controlling the geometric, physical and mechanical parameters of the object. The article presents the principle of operation and functions of an automated measuring device. The article describes the factors that affect the control process by an automated measuring device. (Conclusions) It was found that the use of contactless methods and quality control tools for spare parts of agricultural machinery could improve the accuracy and productivity of control and eliminate the influence of human factors on the measurement process. Timely quality control of spare parts of agricultural machinery using an automated measuring device will allow to identify low-quality or counterfeit spare parts before installation on the repaired equipment, which will reduce the risk of failures of agricultural machinery.

ANALISIS KEANDALAN DAN PENENTUAN PERSEDIAAN OPTIMAL SUKU CADANG COMPRESOR TWO STAGE FOR VESSEL IQF DENGAN METODE ABC DAN RELIABILITY DI PT.KELOLA MINA LAUT

The Production process PT. Kelola Mina Laut has often had obstacles of not working operation of production systems ( production stop because of the problem at bottleneck or breakdown ). This happens because the breakage production machine or waiting for engine unit/component ordered and purchased to replace the faulty component. Especially on machine compressor two-stage no 6 for vessel IQF 4 So it required that the optimal inventory control of spare parts. The method used for the determination this component is the ABC classification method and the method Reliability. ABC obtained by the method of classification of class A that is a component Cylinder liner, piston, piston ring, water pump cooling kop and oil pump. From research to get the value of reliability and the optimal amount of spare parts that cylinder liner with 0.005566 reliability value and the rate of failure 0.012. component piston with the reliability value of 0.017 and the rate of failure 0.014. component piston ring with the reliability value of 0.069 and the rate of failure 0.003605. Component water pumps cooling kop with reliability value of 0.04 and the rate of failure 0.001933 and component Oil Pump with reliability value of 0.03 and the rate of failure 0.002274. Component count is required in a year on machine compressor two-stage no 6 for vessel IQF 4 is 4 units Cylinder liner,5 units of pistons, 1 unit piston ring, 1 unit water pump cooling kop and 1 unit oil pump. With this research can save maintenance costs amounting to 29.86% by a margin price of Rp 37,506,700.00

Using TRIZ to Improve the Procurement Process of Spare Parts in the Taiwan Navy

Abstract: The Naval Maintenance and Repair Command Acquisition Management Unit (NMRC-AMU) of the Taiwan Navy suffered from poor stock control of spare parts and inadequate modification of requested items and manufacturer/part codes during recent years. Therefore, the purpose of this study is to investigate core categorization, coordination, and procurement (CCP) problems, to formulate feasible solutions and then to improve the CCP performances of spare parts in NMRC-AMU. The Teoriya Resheniya Izobreatatelskih Zadatch (TRIZ) method was applied to solve this issue. A problem hierarchy analysis (PHA) was first used to identify the core problems. Then, the 40 principles were used to determine the ideal improvement solution and formulate a solution strategy that simultaneously simplified CCP processed and enhanced the correctness of procurement tasks, thereby elevating CCP efficiency, supporting the Taiwan Navy repair missions, and satisfying fleet maintenance and servicing demands. The results indicated that total 6925 requests for coordination and procurement were submitted. Of these requests, 4366 requests had been completed (with total 102 cases), and the CCP efficiency is 63.0%. After improvement by this study, a total of 4529 items were submitted and 3592 executed items were completed (with a total of 172 cases), and the CCP efficiency is 79.3%. The improvement percentage of the CCP efficiency and completed cases are 30.6% and 68.6%, respectively. The performances are good and the TRIZ could be applied for other military forces.

Spare parts inventory management: New evidence from distribution fitting

Spare parts are necessary for ensuring the functioning of the critical equipment of many companies, and as such, they play a central role in these companies’ operations. Inventory control of spare parts is particularly challenging due to the nature of their demand, which is usually slow-moving, erratic and lumpy. As inventory policies rely on the forecasted lead-time demand distribution and this choice impacts the performance of the system, an ill-suited hypothesized distribution may result in high preventable costs. In this study, we contribute to the empirical literature by analyzing what distributions best fit spare parts demand. We use the Kolmogorov Smirnov (K–S) goodness-of-fit test to find the best-fitting distributions to our data and compare our results to those in the literature. Furthermore, we implement a slightly modified K–S test that places greater emphasis on differences in the right tail of the distribution, mirroring real-world inventory applications, and less emphasis on the left tail. Finally, we link the goodness-of-fit of the distributions to their inventory performance. Our first dataset comes from the German renewable energy industry and is composed of the weekly demand for more than 4000 items over the period 2011–2013. The second dataset comes from the Royal Air Force. It is composed of monthly demand for 5000 items over the period 1996–2002.

OPTIMALISASI KINERJA PERSEDIAAN SUKU CADANG UNTUK PELAKSANAAN MAINTENANCE REPAIR OVERHAUL (MRO) DENGAN PENERAPAN COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEMS (CMMS) (Studi Kasus di PT. Indonesia Asahan Aluminium)

PT.Inalum is a manufacturing company engaged in the aluminum smelting industry. PT.Inalum pengendaliaan system requires an inventory of spare parts to conduct maintenance, repair and overhaul (MRO). CMMS (Computerized Maintenance Management System) is a computerized maintenance system running on a LAN (Local Area Network). CMMS is influenced by three variables, namely an integrated maintenance, inventory and procurement so as to create a good maintenance should be supported by the inventory control of spare parts used in maintenance. CMMS aims to make the work more efficient and effective, especially in matters relating to maintenance. That as a benchmark to measure the performance of CMMs for spare parts inventory control is a key performance indicator (KPI). This study aims to evaluate and compare key performance indicators before and after implementation of CMMS for the implementation of MRO activities. Another goal to be achieved is to determine the factors that affect the value of the inventory of spare parts. Based on the results of data processing and analysis can be seen that by looking at a comparison of before and after implementation of CMMS on key performance indicators, it appears that there is an improvement in every parameter, one of which is the value of the inventory prior to the implementation of CMMS for $ 34,790,000.00 compared to after the application of the inventory value fell to $ 19,632,000.00. Factors that affect the value of the inventory is the inventory of spare parts, maintenance, procurement, and human resources.

Applying ARIMA and Fuzzy Logic to Predict the Electricity Spare Parts Demand

With the development of power industry and the growth of high-voltage power equipments in electric power company, the supply and management of spare parts are becoming more complexity and onerous. This investigation proposed a hybrid method to effectively predict the requirements of electric spare parts utilizing fuzzy logic and ARIMA so as to provide as a reference of spare parts control. The forecasting methods are tested in an empirical, comparative study for an electric power company of China. The results show that the approach is one of the most accurate methods.

Applying moving back-propagation neural network and moving fuzzy neuron network to predict the requirement of critical spare parts

The critical spare parts (CSP) are vital to machine operation, which also have the characteristic of more expensive, larger demand variation, longer purchasing lead time than non-critical spare parts. Therefore, it is an urgent issue to devise a way to forecast the future required amount of CSP accurately. This investigation proposed moving back-propagation neural network (MBPN) and moving fuzzy neuron network (MFNN) to effectively predict the CSP requirement so as to provide as a reference of spare parts control. This investigation also compare prediction accuracy with other forecasting methods, such like grey prediction method, back-propagation neural network (BPN), fuzzy neuron network (FNN), etc. All of the prediction methods evaluated the real data, which are provided by famous wafer testing factories in Taiwan, the effectiveness of the proposed methods is demonstrated through a real case study.

An inventory control system for spare parts at a refinery: An empirical comparison of different re-order point methods

Inventory control of spare parts is essential to many organizations, since excess inventory leads to high holding costs and stock outs can have a great impact on operations performance. This paper compares different re-order point methods for effective spare parts inventory control, motivated by a case study at a large oil refinery. Different demand modeling techniques and inventory policies are evaluated using real data.

Inventory control of spare parts using a Bayesian approach: A case study

This paper presents a case study of applying a Bayesian approach to forecast demand and subsequently determine the appropriate parameter S of an ( S−1, S) inventory system for controlling spare parts of electronic equipment. First, the problem and the current policy are described. Then, the basic elements of the Bayesian approach are introduced and the procedure for calculating the appropriate parameter S is illustrated. We apply the Bayesian approach in an innovative way to specify the initial prior distributions of the failure rates of three types of circuit packs, using the initial estimates and the failure history of similar items. Based on these priors, we determine the distributions of demand for spare parts and finally we calculate the required stock levels for each type at several locations. According to the proposed method, a lower base stock than the one currently used is sufficient to achieve the desired service level.

Inventory control of spare parts in uncertain environment

The problem of inventory control of spare parts in a hierarchical two-level system in uncertain environment is considered. The hierarchical two-level system consists of one central depot and N branch warehouses. A demand of each kind of treated spare parts is uncertain and modeled by fuzzy numbers. A new procedure of classification according to the fuzzy ABC method is developed. The control models are determined for spare parts of great importance. A new fuzzy mathematical model for determining the optimum order quantities of the central depot and branch warehouses is presented. The values of unit procurement price, unit holding costs and unit shortage costs are deterministic. The developed procedure for the classification and the algorithm for determining the optimum order quantities is illustrated by an example.