Spare Parts strategy, methodology
and work plan
Introduction
L. Serio
CERN
Spare Parts strategy, methodology
and work plan
• Scope:
– review the strategy, methodology and work plan to identify and
implement the required spares and quantities for the LHC
cryogenic system
– Agree on:
• what needs to be done and how to do it
• who does what and when
Spares Strategy and Methodology/ 30-March-2015
L. Serio
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Objectives
• Review and agree on:
– Methodology for the identification of the required spares and quantities
• Criticality matrix
• PARETO analysis
– Methodology to review (existing) and identify (new) spare parts and quantities
• Existing spares usage, frequencies and transactions
• BOM
– Strategy to implement
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Collection and review of data
Review and agreement on critical parts and quantities
Required thresholds to be implemented in the GMAO
Implementation via the GMAO, EDMS
– Implementation work plan based on phased approach
• Existing information (spares transactions and usage),
• BOM according to maturity
• Implementation of qualitative and, when available, quantitative FMECA
Spares Strategy and Methodology/ 30-March-2015
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Methodology 1/3
– Criticality of equipment and spare parts is usually established via
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A functional analysis of the system
A FMECA analysis of the process
A criticality analysis of the equipment and parts
A continuous review of the criticality based on the frequency and number of
spares used
– KPI: rotation periods of a part/component/equipment
– We have the disadvantage that there is no analysis or methodology
implemented to define the spare parts and quantities, although we
didn’t have any major problem
– On the contrary we have the advantage of having accumulated a
significant experience (and data) and be able to extract an indicator that
can provide already the overall criticality of spares as well as the
quantities used based on their rotation
– Nevertheless these numbers could be biased by a wrong maintenance
plan or type of corrective interventions
Spares Strategy and Methodology/ 30-March-2015
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Methodology 2/3
– In order to be efficient and perform the work in a reasonable time it is
proposed to perform a phased approach:
• A PARETO analysis of the rotation and quantities of spares based on the 80/20
rule on the quantities and rotation frequency
• Review of the identified spares and quantities via an established criticality
criteria
• Confirmation or adjustment of the spares and quantities as well as
benchmarking and adaptation of the criticality criteria and methodology
– Implement a regular review based on indicators of the rotation of
spares to ensure the up to date information according to the life phase
of the equipment (bathtub graph)
– Once the most critical spares are confirmed, identified, reviewed, the
work can be completed with long term criticality analysis based on the
Bill Of Material starting on the remaining equipment and parts
Spares Strategy and Methodology/ 30-March-2015
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Methodology 3/3
– The analysis shall be based on a set of indicator
(eventually weighted) to be collected to allow first the
selection and secondly the prioritization according to
the impact on the process and the budget available:
• E.g. frequency and quantities, impact, detectability, delay in
procurement, cost)
– It can be progressively improved via the monitoring of
the indicators and the execution of a comprehensive
FMECA analysis for the overall optimization of the
process, availability/reliability and cost
Spares Strategy and Methodology/ 30-March-2015
L. Serio
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Workplan
– Proposal of the methodology, strategy and workplan to achieve the objectives
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SERCO / acceptance CERN
– Adjustment of the criticality matrix and workplan
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SERCO
– Collection of the required data based on the agreed strategy
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SERCO
– Proposal for the review of the selected (PARETO) spares and quantities via the critical matrix
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SERCO / acceptance CERN
– Proposal for the new spares, quantities and thresholds based on the analysis as well as benchmarking the
criticality matrix with the collected indicators
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SERCO / acceptance CERN
– Review of budget implication
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CERN
– Implementation in GMAO and EDMS (new quantities via contractual amendment)
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SERCO and CERN
– Review of the remaining spares based on the BOM with the same criticality matrix
Spares Strategy and Methodology/ 30-March-2015
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Agenda
• 14:00 – 14:05: introduction and scope – Luigi
• 14:05 – 14:35: methodology and workplan for the
identification of the required spares and quantities for the
cryogenic installations – SERCO
• 14:35 – 14:50 – Q&A - all
• 14:50 – 15:15: review and finalisation of the proposal - all
• 15:15 – 15:30: conclusion, next step and identification of
stakeholders (authors, reviewers, informed, approver(s)) Luigi
Spares Strategy and Methodology/ 30-March-2015
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