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2.4 MANAGEMENT OF THE SPARE PARTS

Spare parts Management plays an important role in achieving the desired

plant availability at an optimum cost. Presently, the industries are going for
capital intensive, mass production oriented and sophisticated technology. The
downtime for such plant and machinery is prohibitively expensive. It has been
observed in many industries that the non-availability of spare parts, as and when
required for repairs, contributes to as much as 50% of the total down time. Also,
the cost of spare parts is more than 50% of the total maintenance cost in the
industry. It is a paradox to note that the maintenance department is complaining
of the non-availability of the spare parts to meet their requirement and finance
department is facing the problem of increasing locked up capital in spare parts
inventory. This amply signifies the vital importance of spare parts management in
any organisation.

The unique problems faced by the organisation in controlling/

managing the spare parts are as follows. Firstly, there is an element of
uncertainty as to when a part is required and also the quantity of its requirement.
This is due to the fact that the failure of a component, either due to wearing out or
due to other reasons, cann ot be predicted accurately. Secondly, spare parts are not
that easily available in the market as they are not fast moving items. The original
equipment manufacturer has to supply the spares in most of the cases. New models
are introduced to incorporate the design improvements and old models are
phased out. Hence the spares for old models are not readily available.
Particularly, this is more so in case of imported equipment as the design changes
are taking place faster in the developed countries. Thirdly, the number and
variety of spare parts are too large making the close control more and more
tedious. For instance, the number of items of spares in a medium scale
engineering industry may be around 15,000 and that in a large scale chemical

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industry may be around 100,000. Fourthly, there is a tendency from the stage of
purchase of the equipment to the stage of the use of the spare parts, to
requisition spare parts more number than that are actually required and
accumulation of spares takes place. Finally, the rate of consumption of spare
parts for some are very high and for some are very low. These problems are to be
faced by systematic spare parts management.

There is a need for systematic actions while managing spare parts as given
below:
a. Identification of spare parts

b. Forecasting of spare parts requirement

c. Inventory analyses
d. Formulation of selective control policies for various categories
e. Development of inventory control systems
f. Stocking policies for capital & insurance spares
g. Stocking policies for rotable spares or sub-assemblies
h. Replacement policies for spare parts
i. Spare parts inspection
j. Indigenisation of spares
k. Reconditioning of spare parts
l. Establishment of spare parts bank
m. Computer applications for spare parts management.

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IDENTIFICATION OF SPARE PARTS

When a spare part is required to put back in operation an equipment

which is under breakdown, it becomes necessary to identify the part for getting
the same issued from the store or for purchasing the same from the vendor.
While identifying it becomes essential to give the complete description
including the size and type of the spare to draw from the stores and it becomes
essential for all concerned ie., the maintenance personnel and stores personnel are
aware of such description. If it is the vendor, he may not be satisfied with the
description and he may also require the manufacturer's part number.

It is a cumbersome and time consuming task during every transaction to

identify a spare part by its description and manufacturer's part number
accompanied by the parent equipment's name, make and model designation.
Therefore, it is essential to give a numerical name or code to each spare part. This
process of giving code to each spare part is called codification. In addition to
codifying the spare part, it will be of immense benefit to codify the location of
spare parts. Stock location number helps the stores personnel to locate the part
and issue the same as and when the same is requisitioned. Also the stock
verification and upkeep programme becomes less and less cumbersome.

Advantages of a good Coding system:

The principal advantages of a good coding system are as given:
1. Avoids repeated use of long descriptive titles
2. Accurately identifies all items
3. Prevents duplication of items
4. Helps in standardization and reduction of varieties
5. Forms a convenient basis for the sorting and recording of documents
6. Simplifies mechanical recording
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7. Simplifies pricing and costing

8. Useful in locating particular item in store house

Methods of Codification
The different types of codification systems are the following:

1. Alphabetical System:
In this system, letters are chosen to represent particular classes. Where
relatively few classifications are involved, this method can be used. In this
system code are so assigned as to permit easy memorization. For example:

Code Items
MSC Machine Screw Copper
MSB Machine Screw Brass
EFLS Electric Fan Large Switch
EFSB Electric Fan Small Bearings

2. Simple Numeric Sequence System:

In this system, the serial number is maintained in sequence. Each time a
new type of material is requires the next higher number in the sequence.

Code Items
101 1/8” Machine Screw 1”
102 1/4" Machine Screw 1”
103 1/2" X 10’ Galvanized

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3. The numeric system:

This system is also called group system. In this system the first or basic
numbers indicate specific classes while subsequent digits describe sub-
classification. For instance the basic digits for machine blot may be 36, the next
two digits may be used to designate the diameter. Additional numbers can
indicate the length.

Code Items
36181 Machine Bolt, 1/8” dia. 1” Long
363815 Machine Bolt, 3/8” dia. 1.1/2” Long

If the user of the code can remember that the basic digit 36 designate
machine bolts, the remainder of the code numbers can be easily remembered as
they are dimensions.

4. Decimal System:
In the decimal system, the numbers are so assigned that each digit
represents a sub-group or sub-account of the previous digit. For example,
an automobile manufacturer may assign the number 16 to an assembled wheel. I
in this case the following code numbers may be used to designate
component parts:

Code Item
16.1 Tyres/Tubes
16.11 Valve Stem
16.111 Valve
16.112 Va lve Caps
16.2 Brake Drum
16.3 Nuts
16.4 Discs

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5. The Block System:

The blocks of numbers are reserved for specify classification. For examples
block numbers 7500 – 7549 may be reserved for basic raw materials, 7600 – 7999
may be reserved for components, parts etc. the assigned numbers are provided to
accommodate subsequent expansion. Many times it happens that this system
lacks the logic behind assigning a particular block numbers of an item.

6. Combination system:
This system consists of various combinations of numerical or decimal
system. For instances, a manufacturer using various grades and thickness is of
plywood may use the following:

Code Items
PW 181 Plywood 1/8” thick 1 st Grade
PW 142 Plywood 1/4” thick 2 nd Grade
PW 383 Plywood 3/8” thick 3 rd Grade

After codifying the spare parts and assigning stock location numbers,
all the users should be made aware of and should be supplied with the
relevant codes and stock location numbers in the form of a spare parts
catalogue. The spare parts catalogue should contain the following
information:
Spare parts codification plan
Spare part code
Spare part description
Drawing number
Manufacturer's code & part number
Stock location number

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The spare parts catalogue may be produced in sufficient copies so as to

make available for all the users such as the maintenance personnel, stores
personnel and purchase personnel. This is a very important aspect often neglected
in the organisation. The next step in identification of spare parts is to put an
identification tag or mark with the code to enable the stores personnel identify
during the time of issue. If sufficient care is not taken to incorporate the code, a
lot of time is spent in locating the part and that time is actually added to the
down-time which is really very expensive in case of vital spare parts. There
are a variety of stickers which are scratch-proof, water-proof and temperature-
proof available in the market. Efforts should be made by the organisations to
make use of such identification tags and it will go a long way in reducing the
downtime.

INVENTORY ANALYSIS AND SELECTIVE CONTROL

For the successful spare parts management, it is essential to analyse the
spare parts inventory based on various characteristics such as the frequency
of issues, the annual consumption value, the criticality, the lead time and the
unit price. This is essential as it would not be possible to exercise the same type
of control for all items and it may not really be effective. Inventory analysis aids
selection of policies for selective control. Here at Machine Shop both FSN analysis
and VED analysis were done.

FSN Analysis:
Classification based on Frequency of Issues/Use:-
F, S & N stand for Fast moving, Slow moving and Non- moving items.
This form of classification identifies the items frequently issued, less
frequently issued for use and the items which are not issued for longer period,
say, 2 years. For instance, the items can be classified as follows:

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Fast Moving (F) = Items that are frequently issued

say more than once a month.

Slow Moving (S) = Items that are issued less than once a month.
Non-Moving (N) = Items that are not issued\used for more than 2 years.

This classification helps spare parts management in establishing most

suitable stores layout by locating all the fast moving items near the dispensing
window to reduce the handling efforts. Also, attention of the management is
focused on the Non-Moving items to enable decision as to whether they are
required in the future or they can be salvaged. Experience shows that many
industries which are more than 15 years old have more than 50% of the stock as
non-moving spares.

Even if a few of them are disposed off and the locked up capital is made
available, it will make available additional working capital to the organisation.
Action for disposal should be taken based on the value of each item of spare.

VED Analysis-
Classification Based On Criticality:
Several factors contribute to the criticality of a sparepart. If a spare is
for a machine on which many other processes depend, it could be of very
vital importance. Also if a spare is, say, an imported component for which
procurement lead time could be very high its non-availability may mean a
heavy loss. Similarly spares required for fighter aircraft at the time of war
could be of great value in terms of fighting capability. In general, criticality of
a spare part can be determined from the production downtime loss, due to
spare being not available when required.

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Based on criticality, spare parts are conventionally classified into three

classes, viz. vital, essential and desirable.

VITAL (V) : A spare part will be termed vital, if on account of its

non-availability there will be very high loss due to production downtime and/or a
very high cost will be involved if the part is procured on emergency basis. In a
process industry, most spare parts for the bottleneck machine or process will
be of vital nature. For example, bearings for a kiln in a cement plant will be
considered vital.

ESSENTIAL (E) : A spare part will be considered essential if, due to its
non-availability, moderate loss is incurred. For example, bearings for motors of
auxiliary pumps will be classified as essential.

DESIRABLE (D) : A spare part will be desirable if the production loss is

not very significant due to its non-availability. Most of the parts will fall under
this category. For example, gaskets for piping connection.

The VED analysis helps in focusing the attention of the management on

vital items and ensuring their availability by frequent review and reporting. Thus,
the downtime losses could be minimized to a considerable extent.

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CHAPTER 3

ANALYSIS AND INTERPRETATION

3.1 SPARE PARTS CATALOGUE FOR MACHINE SHOP

The objective of this project was to understand the maintenance procedures

followed in the Machine Shop and to analyze the maintenance problems prevailing
here. As part of the project, a task was there to codify each spare parts used and to
prepare a spare parts catalogue for the machine shop.

The machine shop of Peekay Steel Castings Pvt. Ltd has seven
machineries. First one is TOS make Horizontal Boring Machine. Also there are
four Vertical Turret Lathes and two radial Drilling machines. As part of the spare
parts catalogue preparation, the different spare parts used in the machine shop were
identified and was able to differentiate almost 200 spare parts. These spares were
then classified based on their criticality and based on their frequency of use. For
classifying the spare parts based on their criticality, VED analysis was used and for
classifying the spare parts based on the frequency of use, FSN analysis was used.
Using VED analysis the spare parts were classified into Vital, Essential and
Desirable and using FSN analysis the spare parts were classified into Fast-moving,
Slow-moving and Non-moving. Using these two analysis it were able to classify
the spare parts into nine different groups.
V E D
F VF EF DF

S VS ES DS

N VN EN DN

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We have seen different types of codification system used in the industry. A

combination system of coding was done here which consists of both letters and
numbers. This was done to make the code so simple so that every personnel
working there can easily understand and detect them. Also FSN and VED analysis
is given in the code name so that a personnel on seeing the code tag tied on the
spare part can understand weather it is vital and fast moving, vital and slow
moving, desirable and fast moving etc.

The first three letters of the code is MNT which represents the maintenance
department. The fourth letter classifies the spare part into the following groups -
General, Mechanical, Electrical, Plumbing, Welding or those that are not part of
machine shop ( those that are part of the Katta company). Here the spare parts
belonging to plumbing, welding and that of Katta company were separately kept
because these were not use by the maintenance personnel. Now the spare parts
which are classified into Mechanical, Electrical and General are checked weather
they belong to any particular machinery or whether they are common to all. This is
represented by the fifth letter. The sixth space is given for VED analysis which
helps the concerned person understand that the spare part in his hand is vital,
essential or desirable. The seventh space is used for FSN analysis. These steps
group the spare parts into some common categories. The last two spaces are for
serial numbers which differentiate the spare parts that fall into the same categories
as discussed above. The spare parts catalogue prepared here consists of Spare parts
codification plan, spare parts code, spare parts description, stock location number
and the number of spare parts currently available.

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SPARE PARTS CATALOGUE:

G
M V1
E V2
G V3 V F Seri
MNT W V4 E S al
P H1 D N Num
K R1 ber
R2
L

G - General
V1 - Vertical
Turning Lathe 1
V2 - Vertical
Turning Lathe 2
V3 - Vertical
M - Mechanical Turning Lathe 3 F - Fast
E - Electrical V - Vital moving
MNT - V4 - Vertical E-
G - General Turning Lathe 4 S - Slow
Maintenan Essential
W - Welding H1 - Horizontal moving
ce D-
P - Plumbing Boring Machine N - Non
K - Katta Desirable moving
R1 - Radial
Company Drilling Machine1
R2 - Radial
Drilling Machine2
L - Lathe

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QUANTIT
LOCATIO Y
N AVAILAB
CODE DESCRIPTION NUMBER LE
MNTMLVN 01 Lathe Spare Motor 2.2/3.0 C6 1
MNTMV1ES 01 Rubber Oil Seal (90, 120, 13) S5 4
MNTMV1ES 02 Rubber Oil Seal (60, 130, 13) S5 2
MNTMV2VN 01 VTL2 Gib X axis C5 2
MNTMV2VN 02 VTL2 Gib Y axis C5 2
MNTMV2VN 03 VTL2 Gib Z axis C5 2
MNTMV2VN 04 Bearing 6313 C6 1
MNTMV2VN 05 Bewel Gear for VTL2 C5 2
MNTMV2VN 06 VTL2 Housing C5 1
Coupling Rubber Bush (Taper and
MNTMV2EN 01 Straight) C6 2
MNTMV1/V4ED Rubber Rod (1200x52mm) C6 0
MNTMV3VN VTL3 Turrent Locking Plate C5 1
MNTMV4VN VTL4 Check Gearbox MainShaft C5 1
MNTMV4VN VTL4 Housing C5 1

Grub Screw Sizes - 3/4"x 1/2",

MNTMGVF 01 3/4"x 1" S5
MNTMGVF 02 Teflon Tape S2 2
MNTMGVF 03 Thread Locker S2 2
MNTMGVS 01 Bearing 6209 C6 2
MNTMGVS 02 Bearing N313 ECP/C3 C6 1
MNTMGVS 03 Bearing 51316 C6 2
MNTMGVN 01 Bearing 6204 C6 1
MNTMGVN 02 Bearing NJ317ECJ C6 1
MNTMGVN 03 Bearing 6317 C6 1
MNTMGVN 04 Bearing 6305 C6 2
MNTMGVN 05 Bearing 3622 C5 1
MNTMGVN 06 Bearing 6205 S5 1
MNTMGVN 07 Brass Gib Lock C5 1
MNTMGVN 08 Gib Pin C6 2

MNTMGES 01 Leg (Small) S1

MNTMGES 02 Leg (Big) S2
MNTMGEN 01 Brass Plate (260x16x22mm) C5 1
MNTMGEN 02 Brass Plate (39x26x22mm) C5 1
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MNTMGEN 03 Copper Plate (180x150x6mm) C6 1

MNTMGEN 04 Round Copper Plate C6 1
MNTMGEN 05 Tuflon Rod S6 1 Set
MNTMGEN 06 1/2" Elbow Brass S6 1 Set
MNTMGEN 07 1/4" Brass xniple S6 1 Set
MNTMGEN 08 1" Ball Valve S6 1 Set
MNTMGEN 09 Hose Nipple (brass) S6 1 Set
MNTMGEN 10 1" Hex nipple S6 1 Set
MNTMGEN 11 1/2" Hex Nipple (Brass) S6 1 Set

MNTMGDN 01 Lubrication Pipeline C6 1

MNTMGDN 02 Coolant Pump 15HP C6 1
MNTMGDN 03 Copper Tube 6x8mm C13 1
MNTMGDN 04 Copper Tube 6x4mm C13 1
MNTMGDN 05 Copper Tube 4x2mm C13 1
MNTMGDN 06 Lubrication Pump (old) C6 1
MNTMGDN 07 Stay Wire Clamp C6 2
MNTMGDN 08 Limit Stopper S5 2
MNTMGDN 09 Air Gun S5 9
Neumatic Grinder handle (old-1,
MNTMGDN 10 new-1)

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LOCATIO
N
CODE DESCRIPTION NUMBER QUANTITY
MNTEV1VF VTL1 DC Motor Carbon Brush S1 1
MNTEV1VN Pressure Switch S1 1
MNTEV1/H1VS Potentiometer VTL1/HB S1 3
MNTER1/R2VS Bottle Fuse (10 amps) -
01 RD1/RD2 S2 2
MNTER1/R2VS
02 Bottle Fuse (6 amps) - RD1/RD2 S2 1
MNTER1/R2VS
03 Bulb 24V 60W S3 2

MNTEGVF 01 1.5 Square mm 1 Core C9 1

MNTEGVF 02 1.5 Square mm 3 Core C9 1
MNTEGVF 03 1.5 Square mm 6 Core C9 1
MNTEGVF 04 Carbon Brush S1 10
MNTEGVF 05 Insulation Tape (old-1, new-1) S2 2
MNTEGVF 06 MN2 Relay (4.5-7.5 A) S4 1
MNTEGVF 07 Glass Fuse (1, 2, 3, 5 amps) S2 1

MNTEGVS 01 1.5 Square mm 2 core C9 1

MNTEGVS 02 1350VA Transformer C17 1
MNTEGVS 03 150W Halogen Bulb and Case C14 1
MNTEGVS 04 2.5 Square mm 2 core C9 1
MNTEGVS 05 2.5 Square mm 3 core C9 1
MNTEGVS 06 250W MH Lamp S3 3
MNTEGVS 07 400W MH Lamp S3 2
MNTEGVS 08 Add on Block (1 NO + 1 MC) S4 3
MNTEGVS 09 Bridger Rectifier C17 1
MNTEGVS 10 Halogen Bulb S3 1
MNTEGVS 11 Halogen Bulb Case C14 2
MNTEGVS 12 Halogen Lamp (150W) S3 2
MNTEGVS 13 Josch Armature and Brush S1 1
MNTEGVS 14 Lead S3 1
MNTEGVS 15 Lead and Soldery Paste S3 1
MNTEGVS 16 Limit Switch (new) S1 2

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MNTEGVS 17 Metal Halide Lamp Cup C14 1

MNTEGVS 18 MN2 Relay (2-3.3A) S4 1
MNTEGVS 19 MN2 Relay (4-6.5A) S4 1
MNTEGVS 20 Relay (24V DC) S4 1
MNTEGVS 21 Relay 48V S4 1
MNTEGVS 22 Sodium Fitting C14 2

MNTEGVN 01 0.063 KVA Transformer C17 1

MNTEGVN 02 0.16 KVA Transformer C17 1
MNTEGVN 03 1 KVA Transformer C17 1
1(gone for
MNTEGVN 04 260 VA Transformer C17 repair)
MNTEGVN 05 500 VA Transformer C17 1
MNTEGVN 06 Cable Tray C10 1
MNTEGVN 07 Contactor (3TF50) S1 1
MNTEGVN 08 Contactor 10A (MNX 18) S4 1
MNTEGVN 09 Fuse 32A (FSA) S2 4
MNTEGVN 10 Fuse 32A (HF) S2 4
MNTEGVN 11 Fuse 63A (FSA) S2 3
MNTEGVN 12 Fuse 63A (HF) S2 4
MNTEGVN 13 Fuse 6A (EIT) S2 7
MNTEGVN 14 Isolator ON/OFF Switch C10 1
MNTEGVN 15 Old Limit Switch (ok) S1 1

MNTEGEF 01 4 Square mm 6 Core C9 1

MNTEGES 01 250W Choke S3 2

4 Pole Control Contactor 32A
MNTEGES 02 220V S4 1
MNTEGES 03 Bulb 60W S3 1
MNTEGES 04 Capacitor 08MFD S3 1
MNTEGES 05 Capacitor 42MFD S3 3
Contactor 32A 220V
MNTEGES 06 (telemechanique) S4 1
Flourescent tube choke and
MNTEGES 07 starter S3 1
MNTEGES 08 Halogen Bulb Holder 16A S3 3
MNTEGES 09 HRC Fuse 50A (Bussmann) S2 3
MNTEGES 10 HRC Fuse 63A (HN00) S2 1
MNTEGES 11 MCB 2 Pole 04A S2 2
MNTEGES 12 MCB 2 Pole 10A S2 2
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MNTEGES 13 MCB 2 Pole 16A S2 4

MNTEGES 14 MCB 3 Pole 06A S2 2
MNTEGES 15 MCB 3 Pole 63A S2 3
MNTEGES 16 MCB 4 pole 63A S2 1
MNTEGES 17 MNX Contactor's Coil 110V S4 3
MNTEGES 18 MNX Contactor's Coil 415V S4 1

MNTEGEN 01 16 amps Plug S4 5

MNTEGEN 02 18 Bore Diameter Cooling Fan C13 1
MNTEGEN 03 30 Bore Diameter Cooling Fan C13 1
MNTEGEN 04 4 Square mm 1 Core C9 1
MNTEGEN 05 6 Square mm 1 Core C9 1
MNTEGEN 06 ALMON ARD Exhaust Fan C13 3
MNTEGEN 07 Ammeter S1 1
MNTEGEN 08 Connectors S4 1
MNTEGEN 09 Contactor 10A S4 1
MNTEGEN 10 Contactor 110V (MNX18) S4 1
MNTEGEN 11 Contactor 110V (MNX9) S4 1
MNTEGEN 12 Contactor 3 TF 47 C17 1
MNTEGEN 13 Electronic Timer ETR500 S4 1
MNTEGEN 14 Fuse 16A (FGN) S2 6
MNTEGEN 15 Fuse 350A (Bussmann) S2 3
Fuse and fuse carrier FGN Size
MNTEGEN 16 20A S2 3
MNTEGEN 17 HRC Fuse 100A (HN Size1) S2 1
MNTEGEN 18 HRC Fuse 125A (HN00) S2 1
MNTEGEN 19 HRC Fuse 200A (HN Size1) S2 1
MNTEGEN 20 HRC Fuse 250A (Size 1) S2 3
MNTEGEN 21 HRC Fuse 80A (HN00) S2 2
MNTEGEN 22 MCB 1 Pole 06A S2 3
MNTEGEN 23 MCB 1 Pole 10A S2 1
MNTEGEN 24 MCB 2 Pole 06A S2 1
MNTEGEN 25 MCB 3 Pole 16A S2 1
Micon Electronic ON Delay
MNTEGEN 26 Timer S4 1
MNTEGEN 27 NH2 Fuse 400A S2 6

Cable Glant
MNTEGDN 01 1 3/4 C10 3
1 1/8 C10 7
1 1/4 C10 14
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1 3/8 C10 10
2 1/2 C10 3
2 3/4 C10 3

1” C10 4

2” C10 3
MNTEGDN 02 16 amps 4 Way Switch S1 4
MNTEGDN 03 20 amps Plug C10 3
MNTEGDN 04 3 Pin Universal Socket C10 4
MNTEGDN 05 30 amps Plug C10 3
MNTEGDN 06 4 Way DB C10 1
MNTEGDN 07 6 amp 1 Way Switch C10 15
MNTEGDN 08 8x6" Switch Box C10 3
MNTEGDN 09 Ceiling Rose C10 6
MNTEGDN 10 DB Board With Plug C10 3
MNTEGDN 11 DB Board without Plug C10 3
MNTEGDN 12 DB Box C14 1
MNTEGDN 13 Ignator (old) S3 2
MNTEGDN 14 LT Control Switch C10 1
MCB Metal Clad Plug and Socket
MNTEGDN 15 20A C10 1
MNTEGDN 16 Single Phase DB C10 3
Automatic Drain valve
MNTEGDN 17 Installation S4 1

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LOCATIO
N QUANTIT
CODE DESCRIPTION NUMBER Y
MNTWVS 01 Pressure Regulator (tigmig) C1 1
MNTWVS 02 Gas Preheater Assembly C1 1
MNTWEN 01 Solenoid Valve C1 1
MNTWDN 01 Pottmeter (pankaj) C1 1
MNTWDN 02 Gas Preheater (old) C1 1

MNTPDN 01 20mm Ball Valve C1 1

MNTPDN 02 40mm Ball Valve C1 1
MNTPDN 03 Flot 40mm C1 1
MNTPDN 04 Foot Valve C1 1

MNTKVS 01 CT Motor 5HP C6 1

Gear Coupling (3 ton crane hoist
MNTKVN 01 motor) C6 1
Filter Card for MRD model
MNTKVN 02 Welding S1 1
MNTKVN 03 Wall Mounting Fan C2 1
MNTKEN 01 Tie Rod S1 1
MNTKEF 01 Cable Carrier Trolley C2 1
Almonard Exhaust Janback
MNTKDN 01 sideup C2 1

MNTGGVF
01 CRC (old-1, new-1) S2 1
MNTGGVF
02 Rustlick 631 S2 1

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MNTGGVF
03 CTC S2 1
MNTGGVF
04 M seal S2 1
MNTGGVS
01 Anabond Bearing Retainer S2 1
MNTGGVS
02 Anabond 666T Plus (25g, 100g) S2 1
MNTGGVS
03 Shellac S2 1
MNTGGVN
01 Key (1 set) S2 1
MNTGGEF
01 Marker (White Board) S2 1
MNTGGEF
02 Permanent Marker S2 1

3.2 SWOT ANALYSIS

STRENGTHS
Presence of experienced persons.
Large adaptive labour force.
Just in time production.
Better employee-employer relationship.
Better feedback system.
Excellent reputation
Efficient maintenance management team in the company.
Well-developed Quality control system in the company
Environmental and safety award winner.

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WEAKNESSES
The safety measures must be strictly implemented inside the foundry
No medical centre in the company.
Scraps not stored properly.
Pattern storage need more space.

OPPORTUNITIES
Availability of raw materials in large quantity.
The steel consumption is found to grow in near future.
Maximum exploitation of export market.

THREATS
High competition.
Government regulations.
Environment is not as friendly; as in rainy season, premises full of water.
CHAPTER 4
FINDINGS AND SUGGESTIONS

4.1 Findings
1. During the last one year, the average percentage breakdown of machineries in
the machine shop follows a zigzag curve.
2. During August 2009 the machineries were not available for only 0.42% of the
available time. But September 2009 showed the highest breakdown and during
this month the machineries were not available for 8.15% of the available time.
3. Due to heavy work load, when proper maintenance is neglected for a month,
the next month showed a huge non-avilability of that particular machine.

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4. During the last one year, Vertical Turning Lathe – 2(VTL1)was under
breakdown for 13 times and it was not available for 246.4 hours of the total
availability time.
5. During the last one year, Vertical Turning Lathe – 1(VTL2) was under
breakdown for 10 times and it was not available for 63 hours of the total
availability time.
6. During the last one year, Horizontal Boring Machine(HB1) was under
breakdown for 6 times and it was not available for 137 hours of the total
availability time.
7. Radial Drilling Machine 1 & 2 had the least number of breakdowns.
8. The crane used inside the machine shop had a frequent number of breakdowns
during the last two months.
9. It was not able to identify all the spare parts of the machines as the machines
are very old.
10. Spare parts were not sored in an orderly manner.
11. Machine shop follows breakdown, preventive and routine maintenance now.

4.2 Suggestions

1. It is clear that VTL1, VTL2, and HB1 has been undergone frequent
breakdowns. So more focus on maintenance should be given to them.
2. In the machine shop, the Vertical Turning Lathes work for most of the time.
Therefore proper preventive and routine maintenance should be given to them.
3. The routine maintenances should not be avoided even though there is lot of
pending works.
4. For moving the castings in the machine shop crane has to be there.
Breakdown of the crane could delay the working of all machinery in the
machine shop. So try keeping the breakdown of crane to zero.
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5. VTL1, VTL2, HB1 are the oldest machineries in the machine shop.
Therefore proper routine and preventive maintenance should be given to them.
6. Identify all the new spare parts, codify them and add them in the spare parts
catalogue.
7. Always update the spare parts catalogue periodically and give importance to
the vital and fast moving spare parts as their stock should always be there.
8. Put an identification tag or mark with the code to enable the stores
personnel identify during the time of issue. If sufficient care is not taken to
incorporate the code, a lot of time is spent in locating the part and that time
is actually added to the down-time which is really very expensive in case
of vital spare parts.
9. Try to achieve autonomous maintenance by making the breakdowns nil.

4.3 CONCLUSION

• Maintenance is very important for proper and prolonged functioning

of the machineries. Therefore predictive, preventive and routine
maintenance should be given at proper time.
• VTL1, VL2 and HB1 had the large number of breakdowns during the
last year. Proper caring has to be given to them.
• Managing the spare parts is important as it prevent duplication of the
spare parts. To prevent duplication, it is essential to give a numerical
name or code to each spare part.
• The spare parts catalogue may be produced in sufficient copies
so as to make available for all the users such as the maintenance

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personnel, stores personnel and purchase personnel. This helps them

to easily locate the spare part.
• For the successful spare parts management, it is essential to analyse
the spare parts inventory based on various characteristics such
as the frequency of issues, the criticality etc.
• The VED analysis helps in focusing the attention of the
management on vital items and ensuring their availability by frequent
review and reporting. Thus, the downtime losses could be
minimized to a considerable extent.
• FSN analysis helps in establishing most suitable stores layout by
locating all the fast moving items near the dispensing window to
reduce the handling efforts. Also, attention of the management is
focused on the Non-Moving items to enable decision as to whether
they are required in the future or they can be salvaged.

BIBLIOGRAPHY

• Richard B Chase, “Operations Management for Competitive Advantage

Ninth Edition”, Tata McGraw-Hill
• S N Chary, “Production and Operations Management”
• Naresh K Malhotra, “Marketing Research Fifth Edition”, Pearson Education
• Ministry of Steel, “Annual Report 2009-10”, Government of India
• www.steel.nic.in
• www.peekaysteel.com
• www.productivity.in

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