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Objective improvement number 4: Errors in spare parts orders decreased from 21% to 6%


  • DATA COLLECTION METHODOLOGY
    • The following statistics were produced by accessing the production environments of those customers who participated in this case study.
    • Our products have a transaction LOG, a logbook from which it is possible to take measurements prior to the start and use of our products, and thus trace the evolution achieved over time.
    • For confidentiality reasons, we do not name customers, the repair centers or plants where each piece of data collected was produced.
  • STATE CALCULATION BEFORE USING OF OUR PRODUCT
    • The collection of measurementsrelated to the reduction of errors when making the spare parts listprior to the implementation of our product was based on 5 sources:
    • Manually-done spreadsheets
    • Manual delivery notes and/or records of delivery notes in applications (ERP/supply chain expert systems).
    • Inventory of spare parts in the warehouse.
    • Records/ calculations of the time items remain in stock.
    • Records of rejection of returns by the manufacturer/supplier of the spare parts.
  • USAGE TIME IN CUSTOMER DATABASE
    • Months of USAGE: 380
    • Processed WO: 1,244,580
    • Scheduled tasks: 19,913,265
    • Quality controls (checklist): 842
    • Plants/Workshops: 21
    • Users: 750
    • Planners: 18
    • Integrated ERP: 4
  • OBJECTIVE IMPROVEMENT
    • Errors in spare parts orders decreased from 21% to 6%.
    • It reduces or eliminates idle time while waiting for the correct spare part.
    • It reduces the critical path of repairs that require new spare parts.
    • Decreases direct cost per repair.
    • Increases overall shop productivity.
    • Optimizes the need for and dedication of technicians and shifts.
    • Increases the active usage time of eachpiece of equipment.
  • FUNCTIONS OF OUR PRODUCTS THAT DIRECTLY CONTRIBUTE TO SUCH IMPROVEMENTS
    • “The online request module” avoids errors in spare parts requests, preventing the productivity loss associated with delays during the replacement of a damaged part and, consequently, the extension of the duration of the operating task.
    • Direct communication connectors with the manufacturer’s software allow the operator to be 100% confident about the spare part they request for on-the-go repairs.
    • The visual tools “task board” “WO board” are made available to technicians to allow them to have at hand the standards defined by the manufacturer for each repair, and to download video tutorials and images to maximize their efficiency. As a consequence, technical doubts as well time lost in the search for appropriate support are eliminated, which has a direct impact on the total repair time.
    • The management of “service letters.”
  • More? QPLUS QPSuite is completely designed to bring efficiency to the workshop. (https://qplusglobal.com/eng/qpsuite/ )