ABB Parts Fingerprint

Reduce risk of production loss and increase purchasing power

Understanding parts inventory management is critical to preventing production loss due to missing or outdated parts. The ABB Parts Fingerprint evaluates parts management processes to find deficiencies and applies global best practices to resolve them.

An effective parts management program including inventory procurement, storage, consumption and replacement, helps manage risk and reduce cost. The ABB Parts Fingerprint reviews parts management processes to identify risks to production as well as cost savings opportunities. Risk and cost can be attributed to insufficient stock, over stock, out-of-date inventory, and end-of-lifecycle issues.

Features Benefits
Historical review of usage and purchasing patterns Identifies downtime losses and replacement delays, so deficiencies can be addressed
Inventory documentation and validation Improves purchasing efficiency, optimizes inventory and identifies savings
Inventory risk assessment and gap analysis            Improves preventive/corrective maintenance and matches spares to needs
Recommendations for cost savings Purchasing efficiencies and lower prices, transportation costs and downtime

Reference
US Chemical company justifies upgrade using Parts Fingerprint

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Approach to ABB Parts Fingerprint

1. Recommended Spares

The ABB Parts Fingerprint initial assessment involves capturing detailed equipment configurations, including all associated part numbers and descriptions. The assessment includes:

  • Parts and inventory
  • Historical usage
  • Part/serial numbers

The assessment then categorizes risk by assigning each part a ranking of high, medium or low based on criticality, stage in the lifecycle or obsolescence. Each ranking indicates the risk of production interference or unscheduled downtime.

The recommended spares list provides a snapshot of required parts inventory and the associated risk to facilitate procurement planning. To fully gauge potential risk to production, it is necessary to compare the recommended inventory levels against actual onsite inventory.

2. Gap Analysis

A Gap Analysis can be conducted to compare part stocking levels to production requirements. A physical audit is performed to measure the quantity and quality of parts inventory. Parts requirements and usage history are also compiled and integrated into a database to manage future requirements. The Gap Analysis reviews:

  • Optimum spares levels
  • Parts sustainability
  • Lifecycle status
  • Supportability
  • Criticality

The Gap Analysis uses the Recommend Spares list as a benchmark for the parts audit and exposes any gaps, so part levels can be adjusted to support optimum production. Cost-effective sourcing options to address inventory deficits is vital to prevent downtime due to missing parts.

3. Supply Analysis

In Supply Analysis, gap findings are measured against the supply chain to produce purchasing recommendations based on equipment availability, access to replacement parts and risk of obsolescence. Each step in the supply chain is evaluated to identify the most efficient sourcing options and to find cost savings opportunities. The Supply Analysis reviews:

  • Procurement patterns
  • Vendor selection
  • Purchase price variances
  • Supply management costs
  • Warranty/version/obsolescence status
  • Warehousing/storage
  • Security/inventory shrinkage

A collaborative action plan is implemented to streamline the parts management process and promote procurement efficiencies. Recommendations are made to manage equipment lifecycle status and sustainability.

ABB Parts Fingerprint audits are recommended for the following ABB equipment types:

  • Analyzers
  • Brakes
  • Control Systems
  • Conveyor Systems
  • Drives
  • Electrical Equipment
  • Electro-Magnetic Stirrers
  • Gearless Mill Drives Systems
  • Instruments
  • Laboratory Gauges
  • Measurement Products
  • Mine Hoists
  • Motors
  • Power Products
  • Quality Control Systems
  • Ring Mill Drive Systems
  • Robots
  • SCADA Systems
  • Telecomm Systems
  • Web Imaging Systems

An annual ABB Parts Fingerprint audit is recommended to maintain parts management improvement. Inventory conditions and lifecycle status can change. Events including upgrades, hardware and software updates, changes in component availability, storage deficiencies and human err or are factors that may influence parts management requirements.

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