Case Study for Inventory Management Implementation

The images below show some of the benefits Strategic Maintenance Planning Ltd. can bring about by implementing an inventory management system, to find out about the kinds of positive changes that Strategic Maintenance Planning Ltd can make for your company and the way in which they are carried out simply read on.

Before... After...

Inventory Management Systems

An engineering store has several key objectives:

Hold Spares to meet planned maintenance
Ensure Spares are available to meet emergency breakdown requirements
To provide these at minimised cost

To meet these objectives there is a requirement for a rationale for assessing the optimum number of components to hold in stores and the optimum time and quantity for re-ordering. This rationale is known as a Spares Inventory Policy and it must take account of the rate of demand for the component (and therefore the number of such components in use in a given plant).

The holding of engineering spares for machines within a process environment is expensive. Money held in stores is dead money until the actual parts are needed. This means that the minimising of money tied up in stores, whilst ensuring service to planned maintenance and breakdown requirements, is essential.

Case Study - Dairy Site - South Wales

Situation Prior to Implementation:

Uncontrolled stores
No ability to find individual items
Parts availability for service as low as 40%
Value of engineering spares in excess of c£600,000
Large quantities of spares for obsolete assets
Large quantities of unidentified stock items
One person / one shift stores person coverage leading to uncontrolled stores access
Stock value estimated with no capability for depreciation of value

Action Taken

'PPM Scoping Phase' completed to identify assets requiring spares holding.
Stores Inventory Policy developed to detail requirements for stock holding.
New stores racking system installed.
Stores arranged by process map area, with main assets assigned to individual racks and shelves.
Each spares item identified and assigned to individual asset or consumable generic category.
Obsolete stock identified, put to one side and auctioned off.
All retained stock labelled and located into new stores structure.
All stock information transferred to HolisTech™ system.
Stores operational procedure implemented to ensure coverage of stores and definition of responsibilities.
Long-term continuous improvement plan developed for site.

Results

Overall stock holdings reduced to c£300,000
Parts availability for service improved by 70% with general upward trend with continuous improvement initiatives
Cyclical monthly stock takes now carried out with variance within 1%
All parts easily found, with no requirement for store person presence.

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Able Breads
ABR Foods
Aircelle (SAFRAN Group)
Airflow Streamlines Ltd.
Alcan
Alcoa
Alcoa CSI UK Ltd.
Allied Bakeries 8 UK Sites
An Post 4 Sites
Apollo Fire Detectors
Artex Blue Hawk Ltd.
Artex Rawplug
Askeys Ltd.
Associated Creameries
B&Q Plc.
B&W Loudspeakers
Baker Group of Companies
Baxenden Chemicals Ltd.
BCA
Bendicks (Mayfair)
Bostik 2 Sites
Bottle Green Drinks Co.
Braces Bakery 2 Sites
Bredero Shaw
Bristol Airport
Bristol Bending Services
British American Tobacco
Bryan Donkin Ltd.
Buckingham Foods
Burlington Slate
Burn Stewart Distillers Ltd.
Calsonic Climate Control Ltd.
Cereform Ltd.
Charnwood Foods
Chevron Texaco - East Midlands Airport
Cisco Systems Int BV.
Cisco Systems UK, Europe & Middle East
City Industrial Waste
Classic Courverture
Coates Electrographics
Coates Electrographics USA
College Gwent
Constellation Europe
Couldron Foods
County Confectionery
Coutts Packaging
DAC Plant
Dairy Crest Haverfordwest
Dalgety Arable
Dartington Foods Plc
Delphi Hungary
Dorset Chilled Foods
Dove Valley Ltd.
Dovecote Park
Dowty Engineered Seals
Ducal Ltd.
Eaton Aerospace
Eaton Hydraulics
Economatics (Industrial) Ltd.
Edinburgh City Council
Edrington Group 5 UK Sites
Element Six Production Ltd.
Elizabeth Shaw Ltd.
Encase Holding Ltd.
Encase Northern
Environmental Agency
Eternit
Euramax
Euro / DPC
Evode Ltd.
Exitech Ltd.
Explore Manufacturing
ExxonMobil 110 Sites Globally
Fenmarc Produce Ltd.
FFP Packaging Ltd.
Field Packaging Ltd.
Fortnum & Mason
Frank Wright Ltd.
Fusion Provida
Games Workshop
Gatwick Airport - Shell Aviation
GEO Adams & Co
GKN Driveshafts
GKN Hardy Spicer
The Cheese Company 4 Sites
GPS UK Ltd.
Grace Construction Products Ltd.
Greene King Brewing & Retailing
Greenway Lubricants Ltd.
Gulf News - Dubai 2 Sites
Hammonds Furniture Ltd.
Hazlewood Chilled Meals
Hazlewood Food Enterprises
Heathrow Airport - H.H.Op. Co.
Heraeus Electro-Nite
Hygrade Foods 2 UK Sites
Iceland Frozen Foods Plc
ID Data Systems Ltd.
Impact Control Systems Ltd.
J&A International
Johnson Controls
Kalmar
Kerry Aptunion
Kerry Foods 2 Sites
Kerry Ingredients
Kerrygold Company Ltd.
La Fornaia
Lafarge Lime
Lanstar Ltd.
Lawson Mardon Packaging
Lawson Mardon Star
Leicester Fire & Rescue Service
LG Philips
Linpac Storage Systems
Linread Automotive Plc.
Lion Foods Ltd.
Magners
Manor Bakeries Ltd.
Marchwood Power Ltd.
McCormick Group 2 UK Sites
Microvue Ltd.
Midland Meat Packers
Mixalloy Ltd.
Moss Plastic Parts Ltd.
Mowlem Technical Services
New Covent Garden Soup Co.
New Milton Sand & Ballast
Northern Foods
Norwich Corrugated Board Ltd 2 UK Sites
Novartis Consumer Health
On-Site Central Ltd.
Paarman Foods - South Africa
Pann Krisp
Parcelforce Coventry Hub
Parrs Confectionery
Paula Rosa Kitchens
Peartree Foods
Permabond
Permadoor
Peters Food Service
Plastic Omnium Automotive Ltd.
Plastics Manchester Ltd.
Polycast Ltd.
Poly-Flex Circuits Ltd.
Polyframe Trade
Poole Harbour Commissioners
Pork Farms Bowyers Ltd.
Pritex Ltd.
PVI Ltd.
Raven Manufacturing Ltd.
Regent GM Laboratories
Reichold UK Ltd.
REW Acton Ltd.
Reylon Ltd.
Richard Burbage Ltd.
Ricon Ltd.
RMH - Avana Bakeries
Roltech ASD.
Royal Doulton (UK) Ltd.
Royal Mail Group
S.A.T.O. (Greece)
S.H. Agricultural Engineers
SCA Packaging Ltd.
Scottish Power
Sekisui (UK) Ltd.
Shanks Chemical Services
Sheffield Care Trust
SIFE Unigate France
Sigma Aerospace Ltd.
Sola Optical (UK) Ltd.
Solo Europe
Spirax Sarco
St. Ivel Ltd.
Stansted Airport - Stansted Fuelling Co.
Stansted Airport - Stansted Into Plane Ltd.
Stanton Plc.
Steetley Dolomite
Still Material Handling Ltd.
T&B Group UK and Europe
Tarmac Topblock Ltd. 2 Sites
Telford Extrusions Ltd.
Telford Foods Ltd.
Harmsworth Press 11 Sites
The Royal Free Hospital
The Royal Mail
Thompson Plastics Group
Tangerine Confectionery 6 Sites
Tornado Pty
Trans World International
TRW Lucas Varity
Tuberex Ltd.
Tucker Fasteners
Tulip UK Ltd. 17 Sites
Tyco
UK AEA Jet Facility
Unigate Dairies Ltd.
Unigate EFG Plc UK and Europe
United Utilities Industrial
UYT
Vibro Meter
Vickers Industrial Products
Vickers Systems
Viking UK Gas
Viridor Waste Management 69 Sites
Visqueen Building Products
VP Automation
W.A. Turner
Watlow Ltd.
WBB Minerals
Whitworth Bros.
Wincanton Logistics
Winkhaus (UK) Ltd.
Woodbridge Foam 3 European Sites
Xyratex
Yoplait Dairy Crest

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