Spare Parts Management

Effective spare parts management is akin to logistical support in a battle. Have you considered the losses incurred due to unexpected machinery or equipment failures during production? What if repair processes are hindered by the unavailability of spare parts?

The losses from production downtime can be quantified, but there are also immeasurable losses, such as damage to company image and client trust.

Therefore, implementing an effective maintenance program and controlling spare parts management is crucial. This includes determining necessary items, assessing the need for storage, identifying suppliers, timing orders, specifying quantities, ensuring quality standards, budgeting for spare parts, and more.

Course Objectives

Participants will be able to:

1. Understand strategies for spare parts provision.
2. Control spare parts effectively.
3. Provide necessary items for overhauls and support operational spare parts needs.
4. Manage spare parts efficiently.
5. Develop a just-in-time stock system with the required specifications.

Who Should Attend

This training is recommended for:

• Maintenance Managers and Staff
• Production Managers and Staff
• Managers or Staff closely related to maintenance resource management, such as Warehouse Management and Supply Chain personnel.

Course Content

1. Strategies for Spare Parts Inventory to Support Production Processes
2. Planning and Managing Spare Parts Inventory
3. Spare Parts Management and Control Strategies
4. Classification of Spare Parts and Equipment
5. Reorder Point Calculation for Inventory & Management
6. Planning and Controlling Spare Parts for Overhaul
7. Stock Control of Spare Parts: Safety Stock, Overstock, and Dead Stock
8. Cost Calculation and Analysis of Spare Parts
9. Effective and Efficient Spare Parts Warehouse Management
10. Software aided inventory
11. Control of Factors Leading to Inventory Loss
12. Spare Parts with Specific Storage Requirements
13. Warehouse layout & racking system
14. Spare Parts Coding and Standardization Systems
15. Key Performance Indicators (KPIs) for Spare Parts Management

About the Course Leader

Ir. Irfan Zen graduated from the Caterpillar Class in Illinois, USA, in addition to earning his Mechanical Engineering degree from ITB and Lemhanas. Following his graduation from Caterpillar, he worked for the company from 1998 to 2011 in Singapore and Indonesia, including at Freeport Tembagapura. Since then, he has become a freelance consultant and trainer.

With nearly 30 years of practical experience in both domestic and multinational companies, Ir. Irfan is dedicated to management consulting and training, particularly in Caterpillar products, operations, maintenance, repair, spare parts management, and reliability engineering.

His clients include PLN, Pertamina Downstream, Pertamina EP, Kideco Mining, Berau Coal, KPUC Mining, Bukit Makmur Mining, Petrogas, PetroChina, Sinar Mas Group, the Indonesian Ministry of Industry, BUMN Karya (PP, Wika, Adhi, Waskita, Haka), PGN, Pelindo, and various international and national oil and gas companies.