NewWordsandExpressionssophisticated [s?'f?st?ke?t?d]adj.復(fù)雜的paradox['p?r?d?ks]n.悖論，自相矛盾的organization[??ɡ?na?'ze???n]n.組織，團(tuán)體manufacturer[m?nj?'f?kt?(?)r?(r)]n.制造商，廠商tedious['ti?d??s]adj.沉悶的，冗長(zhǎng)乏味的codification[kɑd?f?'ke??n]n.整理，匯編vendor['vend?]n.賣(mài)主cumbersome['k?mb?s(?)m]adj.笨重的，難處理的sticker['st?k?]n.張貼物INTRODUCTIONSparepartsManagementplaysanimportantroleinachievingthedesiredplantavailabilityatanoptimumcost.Presently,theindustriesaregoingforcapitalintensive,massproductionorientedandsophisticatedtechnology.Thedowntimeforsuchplantandmachineryisprohibitivelyexpensive.Ithasbeenobservedinmanyindustriesthatthenon-availabilityofspareparts,asandwhenrequiredforrepairs,contributestoasmuchas50%ofthetotaldowntime.Also,thecostofsparepartsismorethan50%ofthetotalmaintenancecostintheindustry.Itisaparadoxtonotethatthemaintenancedepartmentiscomplainingofthenon-availabilityofthesparepartstomeettheirrequirementandfinancedepartmentisfacingtheproblemofincreasinglockedupcapitalinsparepartsinventory.Thisamplysignifiesthevitalimportanceofsparepartsmanagementinanyorganisation.INTRODUCTIONTheuniqueproblemsfacedbytheorganisationincontrolling/managingthesparepartsareasfollows.Firstly,thereisanelementofuncertaintyastowhenapartisrequiredandalsothequantityofitsrequirement.Thisisduetothefactthatthefailureofacomponent,eitherduetowearingoutorduetootherreasons,cannotbepredictedaccurately.Secondly,sparepartsarenotthateasilyavailableinthemarketastheyarenotfastmovingitems.Theoriginalequipmentmanufacturerhastosupplythesparesinmostofthecases.Newmodelsareintroducedtoincorporatethedesignimprovementsandoldmodelsarephasedout.Hencethesparesforoldmodelsarenotreadilyavailable.INTRODUCTIONParticularly,thisismoresoincaseofimportedequipmentasthedesignchangesaretakingplacefasterinthedevelopedcountries.Thirdly,thenumberandvarietyofsparepartsaretoolargemakingtheclosecontrolmoreandmoretedious.Forinstance,thenumberofitemsofsparesinamediumscaleengineeringindustrymaybearound15,000andthatinalargescalechemicalindustrymaybearound100,000.Fourthly,thereisatendencyfromthestageofpurchaseoftheequipmenttothestageoftheuseofthespareparts,torequisitionsparepartsmorenumberthanthatareactuallyrequiredandaccumulationofsparestakesplace.Finally,theratesofconsumptionofsparepartsforsomeareveryhighandforsomeareverylow.Theseproblemsaretobefacedbysystematicsparepartsmanagement.INTRODUCTIONTheobjectiveofsparepartsmanagementistoensuretheavailabilityofsparesformaintenanceandrepairsoftheplantandmachineryasandwhenrequiredatanoptimumcost.備件管理的目標(biāo)是確保設(shè)備和機(jī)器的維修和修理的備件可用性，并在需要時(shí)以最佳成本.

Also,thesparesshouldbeofrightquality.Therearemanyactionsrequiredtoensurethesparepartsmanagementeffective.INTRODUCTIONThereisaneedforsystematicactionswhilemanagingsparepartsasgivenbelow:a.Identificationofspareparts1-2b.Forecastingofsparepartsrequirementc.Inventoryanalysesd.Formulationofselectivecontrolpoliciesforvariouscategoriese.Developmentofinventorycontrolsystemsf.Stockingpoliciesforcapital&insurancesparesg.Stockingpoliciesforrotablesparesorsub-assembliesh.Replacementpoliciesforsparepartsi.Sparepartsinspectionj.Indigenisationofsparesk.Reconditioningofsparepartsl.Establishmentofsparepartsbankm.Computerapplicationsforsparepartsmanagement.INTRODUCTIONEveryorganisationshouldproceedsystematicallyandestablishaneffectivesparepartsmanagementsystem.Codificationhelpstheorganisationminimizingduplicationofsparepartsstockingtherebyreducinginventory,aidstheaccountingprocessandfacilitatesthecomputerisationofsparepartscontrolsystems.Theinventoryanalysescarriedoutonthebasisofdifferentcharacteristicsofthespareparts,suchasannualconsumptionvalue,criticality,leadtime,unitcostandthefrequencyofuse,helpthecompanyinestablishingsuitablepoliciesforselectivecontrol(根據(jù)備件的不同特性，如年消耗量、重要程度、交付周期、單位成本和使用頻率，進(jìn)行庫(kù)存分析，幫助公司建立合適的選擇性控制策略).Thisalsohelpsinfocusingoureffortsonrealproblemareas.INTRODUCTIONAgoodinventorycontrolsystemwillhelpsystemizingtheorderingprocedureandalsoachievinganoptimumlevelofinventory.Inaddition,selectivelyeffortsshouldbemadetoevolveoptimumreplacementpoliciesforselectedspareparts,forwhichcostofdowntimeandcostofreplacementareveryhigh.So,wehavetoidentifysuchsparepartsandcarryouttheexerciseforevolvingoptimumreplacementpolicies.INTRODUCTIONForthesparepartswhichareveryexpensiveandthosewhicharetobeimported,itisessentialthattheusefullifeforsuchsparesisextendedbyappropriateapplicationsofreconditioningandrepairtechniques.Also,effortsshouldbemadetoindigenisethesparepartsinviewofthehard-to-getforeignexchangeinvolvement.Also,forsimilarindustriesestablishingofsparepartsbankgoesalongwayinreducingthetotalinventoryholdingoftheexpensivesparepartsandalsoreducesthestockholdingcost.Fordifferentindustries,itwillbehelpfultoestablishsparepartsbanksandasuitableinformationsystemfortheexchangeofspares.Lately,theapplicationofcomputersfortheprocessingofsparepartsinformationandoperatinganeffectivesparepartscontrolsystemwillbeveryhelpfulfortheorganisationand7-3maintenanceengineeringandmanagementwillensuretimelyactionsforanefficientandeffectivesparepartsmanagement.IDENTIFICATIONOFSPAREPARTSWhenasparepartisrequiredtoputbackinoperationanequipmentwhichisunderbreakdown,itbecomesnecessarytoidentifythepartforgettingthesameissuedfromthestoreorforpurchasingthesamefromthevendor(當(dāng)一個(gè)處于故障狀態(tài)的設(shè)備消耗一個(gè)備件時(shí)，就必須同時(shí)從庫(kù)存或供應(yīng)商處獲得一個(gè)同樣的備件).Whileidentifyingitbecomesessentialtogivethecompletedescriptionincludingthesizeandtypeofthesparetodrawfromthestoresanditbecomesessentialforallconcernedie.,themaintenancepersonnelandstorespersonnelareawareofsuchdescription.Ifitisthevendor,hemaynotbesatisfiedwiththedescriptionandhemayalsorequirethemanufacturer'spartnumber.IDENTIFICATIONOFSPAREPARTSItisacumbersomeandtimeconsumingtaskduringeverytransactiontoidentifyasparepartbyitsdescriptionandmanufacturer'spartnumberaccompaniedbytheparentequipment'sname,makeandmodeldesignation.Therefore,itisessentialtogiveanumericalnameorcodetoeachsparepart.Thisprocessofgivingcodetoeachsparepartiscalledcodification.Since,therangeofsparesusedinanyorganisationistoolargeandtherearequiteafewsparesmeantforspecificequipment,itisalwayspreferredtousecodeswhicharesignificantie.,fromthecodenumberonewillbeabletofindouttheequipmenttype,make&modelthetype/classofthespare-partthesize(insomecases)IDENTIFICATIONOFSPAREPARTSIfthesparepartcodeistoincorporatetheequipmenttypeetc.,thenthecodificationofequipmentbecomesaprerequisiteforsparepartcodification.Thenumberofdigitsrequiredforsparepartcodedependsontheactualrequirementie.,therangeofequipmentinuseandthetypesandnumberofsparepartsintheorganisation.Itisverycommontocomeacross9to16digitcodesforspareparts.Forinstance,a10-digitcodemaysignify,1stdigit-importedorindigenous2nd,3rd&4thdigits-machinetype,make&model5th,6th&7thdigits-spare-partclass8th,9th&10thdigits-sizeorserialnumber.IDENTIFICATIONOFSPAREPARTSByclassifyingandcodifyingallthespareparts,itbecomeseasytominimizetheduplicationofsparepartstherebyeffectingreductionintheinventory.Codificationalsohelpseasyaccountingandcomputerisationinadditiontoeasiercommunicationbetweenconcernedparties.Inadditiontocodifyingthesparepart,itwillbeofimmensebenefittocodifythelocationofspareparts.Stocklocationnumberhelpsthestorespersonneltolocatethepartandissuethesameasandwhenthesameisrequisitioned.Alsothestockverificationandupkeepprogrammebecomeslessandlesscumbersome.IDENTIFICATIONOFSPAREPARTSAftercodifyingthesparepartsandassigningstocklocationnumbers,alltheusers7-4maintenanceengineeringandmanagementshouldbemadeawareofandshouldbesuppliedwiththerelevantcodesandstocklocationnumbersintheformofasparepartscatalogue.Thesparepartscatalogueshouldcontainthefollowinginformation:SparepartscodificationplanSparepartcodeSparepartdescriptionDrawingnumberManu