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Spared Equipment in Process Plants

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  • #68488

    Hartshorn
    Participant

    Your equipment supplier would need to be running a six sigma process (and their suppliers, and then their suppliers…) for you to be able to eliminate your spare equipment.  Even at that reduced risk level, there is still the possibility of a failure.  (I suspect a RTY on equipment that covers all components through the various levels of suppliers would be a real eye opener.)  In my company, it would not take very long for the cost associated with equipment downtime to exceed the cost save realized by reducing or eliminating spare parts (often probably only a matter of a few hours).

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    #68490

    Murray
    Participant

    Reduced – absolutely
    Eliminated – no way

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    #68495

    Jim Johnson
    Participant

    I agree with the other two opinions stated here. I don’t think there is any way that you would want to completely eliminate all spare parts for critical machinery.I do think you should ask your suppliers to work with you and then with their suppliers to get to Six Sigma on your critical parts. It will help reduce their costs and probably their cycle time to produce those parts which in turn will help you in availability, etc.Jim Johnson
    Black Belt

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    #27793

    A.H.
    Participant

    Since Six Sigma will reduce the defects, can I assume that all spares to critical equipment can be eliminated ? This would reduce capital and maintenance costs if that was the case. Equipment redundency was there due to the “just in case this piece of equipment fails” mentality.

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    #68525

    Dewayne
    Participant

    Being in management, I am afraid I am part of that “just in case” mentality mindset, A.H.  Until 3.4 ppm is replaced by guaranteed, absolute perfection, compensation for potential failure of some kind may be needed to assure survival of the organization, when critical issues are involved.  However, the improvement that six sigma can provide should justify increased audits for the reduction of backups when the need has been eliminated.

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