We recently sat down for a conversation with David Cantu, ProcessBarron’s Director of Material Handling. Cantu highlighted the importance of industrial spare parts in ensuring smooth operations and reducing downtime in industrial settings.
He emphasized the importance of understanding the diverse types of spare parts, their applications, and how different sectors like manufacturing and construction utilize them.
We discussed the challenges of managing spare parts inventory. We also looked at ways to improve spare parts management. This included discussing predictive maintenance and digital solutions.
What are Industrial Spare Parts?
A spare part is a replacement part that is kept in inventory and used for repairing and maintaining machinery. There are different types of spare parts, and they’re an important feature of engineering and supply chain management.
ProcessBarron supplies industrial spare parts for equipment such as fans, dampers, drag chain conveyors, screw conveyors, mechanical dust collectors, and precipitators which include parts such as motors, bearings, drag chains, and sprockets, and more, even if we are not the original equipment manufacturer (OEM).
The Role of Industrial Spare Parts
It is important to have a well-organized supply of spare parts for machines. This keeps them running smoothly and efficiently without interruptions or delays. It also prevents losses in production and ensures that the machines last longer.
Spare parts are typically industry-specific, with different parts that go with equipment for each sector. For example, the drag chains that are used in the cement industry are different from those in the conveyor used in a lime plant. Each conveyor needs different parts, based on application, and what material is being handled.
Conversely, spare parts like fan housing, motor, and bearings are common for fans across sectors. Likewise, precipitators and dust collectors use similar style parts. Ultimately, the right selection and application of these parts significantly contribute to operational efficiency.
Understanding Applications of Industrial Spare Parts
The ProcessBarron team members are experts in selecting the appropriate parts for each application and based on plant geography. For example, motors, bearings, and drag chains are vital in manufacturing, but construction applications may have different needs.
Another example? The humid weather conditions in the Southeast affect equipment differently. The ProcessBarron experts have different spare parts that are made just for you, so your operations can keep running smoothly. No matter where your equipment is, we choose the best options to keep your operations running smoothly between outages.
This approach gives advice on what parts you need to start and suggestions for the next two to three years. This will help you have the right products in place and prevent equipment failure.
Challenges of Managing Spare Parts Inventory
Consider the benefits and potential issues of maintaining a large inventory of industrial spare parts. Having spare parts readily available can help replace broken parts quickly. This reduces the amount of time equipment is not in use. It also helps to keep everything running smoothly.
Using industrial spare parts has benefits, but it can also be challenging. One challenge is the need for storage space. Another challenge is investing in parts that may not be used later on. To avoid problems with managing inventory, it is important to have a system in place.
This system should keep track of current stock levels and identify when items need to be restocked. Using industrial spare parts has benefits, but it can also be challenging. One challenge is the need for enough storage space.
Another challenge is investing in parts that may not be used later on. To avoid problems with managing inventory, it is important to have a system in place. This system must track current stock levels and identify items that require restocking.
Sourcing and procurement can be challenging sometimes, especially when dealing with parts from different manufacturers or suppliers. Supply chain issues can arise when sourcing from different countries, such as China and India.
The products may seem cheap at first. However, they can cause issues such as long delivery times.
These delays can hinder completing necessary repairs on time. As a result, expensive downtime may occur. Additionally, cheaper parts may not always meet the necessary quality standards, potentially leading to frequent breakdowns and replacements.
Our high-quality spare parts helped a large paper factory in the Southeast reduce downtime and improve service. The machines at the factory were not working properly before. Our spare parts helped to reduce the amount of time the machines were not working. This ultimately led to better service for the factory.
The paper mill tried using cheaper parts from a competitor. However, these parts caused more downtime and machinery failures. As a result, they decided to go back to using ProcessBarron’s higher-quality parts.
When making sourcing and procurement decisions, it is important to consider both cost and quality. This will help ensure efficient operations and the longevity of industrial equipment.
These issues demonstrate the importance of having a reliable supplier relationship and implementing effective strategies for spare parts management.
Unplanned Downtime Is Costly
A study by VansonBourne found that 70% of companies don’t know when their equipment needs maintenance or upgrades.
His lack of insight can lead to unexpected downtime, which can be quite costly. In fact, unplanned downtime can cost companies $250K per hour. This can create a significant financial strain on businesses, particularly those in manufacturing and production.
The VansonBourne study revealed that for 72% of the 450 organizations that participated, achieving zero unplanned downtime is now a number one or high priority. This shift in focus reflects the growing realization of the significant costs and disruption caused by unexpected downtime.
With unplanned downtime resulting in significant losses, organizations cannot afford to neglect the opportunity to improve. Spare parts are the key to addressing these losses. Below, we’ve outlined strategies for you to implement to help effectively manage your organization’s spare parts.
Strategies for Effective Spare Parts Management
These techniques efficiently track different parts, identify items that need to be restocked, and maintain an organized system.
Predictive maintenance is a key strategy, which anticipates the need for spare parts, thus minimizing potential downtime. For example, materials like sand and biomass can wear out certain parts very quickly.
We choose parts based on the environment they will be in. This includes factors like the location. The goal is to prevent them from breaking during power outages.
ProcessBarron assists customers in identifying the necessary spare parts to keep in stock, considering space limitations and budget constraints. “Customers rely on us to keep a variety of spare parts in stock and we can stock them for you,” said Cantu.
Regular inspections during outages are also crucial as they help anticipate needs. Additionally, establishing reliable supplier relationships is also important, as these partnerships can alleviate sourcing and procurement challenges.
Digital solutions, such as automated reordering systems, can help manage spare parts more efficiently. These solutions ensure that you always have the necessary parts available. These digitized spare parts management processes allow for organized growth and minimized losses.
The ProcessBarron team uses CrewConX, a specialized efficiency software. They use it to track customer data and provide detailed inspection reports on the spare parts needed by customers. This preventative maintenance inspection (PMI) approach enables industries to offer parts before they’re even needed, helping to minimize downtime and generate cost savings.
Final Thoughts
Understanding spare parts and their usage is crucial for maintaining the efficiency of industrial machines and reducing downtime. It is crucial to understand the role of spare parts in maintaining the functionality of machines.
By having this knowledge, you can ensure that machines are always in good working condition. This will help to prevent any disruptions in production and keep operations running efficiently.
Industries such as manufacturing and construction need a good system for managing spare parts. This system helps them keep track of the parts they need and ensures they have them available when needed.
Having a well-organized spare parts system is crucial for these industries to operate efficiently. It allows them to avoid delays and keep production running smoothly. With better spare parts management, you can minimize downtime and reduce costs.
Struggling with managing industrial spare parts? The ProcessBarron team is prepared to help you with our spare parts management strategies. These strategies involve predictive maintenance and digital solutions.
We would be happy to discuss your industrial spare parts and equipment needs. Reach out to us today!