Spare parts inventory management

• US 7,266,518 B2
• Filed: 12/29/2005
• Issued: 09/04/2007
• Est. Priority Date: 12/29/2005
• Status: Active Grant

• Current Assignee: Callahan Cellular LLC (Intellectual Ventures LLC)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Griffin, Monty, Klim, Thomas R.
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): RAO, SHEELA S
• Application Number:
  US11/321,759
• Publication Number:
  US 20070156543A1
• Time in Patent Office: 614 Days
• Field of Search: 700/107, 700/117, 700/236, 705/28
• US Class Current: 705/28
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

A method for managing spare parts and tools for a manufacturing enterprise is disclosed. Historical demand values are statistically analyzed to determine optimal stocking levels for spare parts based upon required availability percentages, parts lead times, and the statistical distribution parts demand levels. Parts stocking decisions can also be based upon planned and preventative maintenance timeframes with such parts ordered on an as-needed basis in accordance with lead times. Spare parts inventory management can utilize an enterprise-wide computer system to integrate parts demand planning with systems used for engineering and other changes to manufacturing processes and facility maintenance systems. The computer system can perform varying degrees of the parts reordering and planning process and automate certain steps while providing for decision of other issues by parts management personnel.

Claims

1. A method for managing enterprise-wide component inventory, comprising the steps of:

a. identifying a plurality of components, each comprising a part or tool used in support of at least one manufacturing process;

b. maintaining at least one inventory store of the components;

c. calculating an enterprise-wide demand plan for each of the components; and

d. adjusting the number of each component maintained in the inventory store based upon the demand plan.

2. The method of claim 1, wherein the step of calculating a demand plan includes responding to a trigger initiated by a change in a component bill of material for a manufacturing process.

3. The method of claim 2, wherein the change comprises deletion of a component from a process, and wherein calculating an enterprise-wide demand plan comprises providing for the inventory store of the deleted component to run out.

4. The method of claim 2, wherein the change comprises addition of a previously-unused component to a process as of an effective date of service, and wherein calculating an enterprise-wide demand plan comprises providing for an initial stocking level of the previously-unused component so that at least one spare of the previously-unused component is available to meet demand as of the effective date of service of the previously-unused component.

5. The method of claim 1, wherein maintaining at least one inventory store includes storing a plurality of components at a central location, and wherein calculating an enterprise-wide demand plan includes determining a safety stock level for the components based upon statistical analysis of prior demand, including lead times for the components.

6. The method of claim 1, further comprising:

tracking a history of a component, and wherein calculating an enterprise-wide demand plan for the component comprises utilizing the tracked history.

7. The method of claim 6, wherein calculating an enterprise-wide demand plan for the component includes utilizing data comprising a frequency of failure of the component.

8. The method of claim 6, wherein tracking a history of a component includes maintaining a record of at least one individual instance of the component.

9. The method of claim 8, wherein maintaining a record includes maintaining a history of repairs to the individual instance of the component.

10. The method of claim 8, wherein maintaining a record comprises identifying a physical location of the individual instance of the component.

11. The method of claim 8, wherein tracking a history of a component includes scanning at least one RFID device associated with the individual instance of the component.

12. The method of claim 5, wherein the central store has a turns ratio greater than 1.

13. The method of claim 12, wherein the central store has a turns ratio greater than 2.5.

14. A method for managing enterprise-wide component inventory, comprising the steps of:

a. identifying demand values for spare parts used in support of a plurality of manufacturing processes located at multiple facilities;

b. maintaining at least one inventory store of the spare parts;

c. separating breakdown demand for each spare part from non-breakdown demand for each spare part;

d. determining an average demand level for each spare part;

e. calculating a theoretical safety stock level for each spare part based upon an analysis of the statistical distribution of breakdown demand values for the part, the planned delivery time for the part, and an availability requirement for the part;

f. calculating a forecast demand for each spare part based upon the average demand level, planned delivery times, and theoretical safety stock level;

g. placing orders for each spare part such that the inventory store contains sufficient numbers of each spare part to meet the calculated forecast demand; and

h. placing orders for each spare part such that sufficient parts are delivered to facilities in accordance with planned delivery times to meet non-breakdown demand.

15. The method of claim 14, wherein the at least one inventory store is a central hub serving multiple manufacturing facilities, and

wherein the parts orders are placed such that the central hub contains sufficient numbers of each spare part to meet calculated demand for all the facilities associated with the hub.

16. The method of claim 14,

further comprising adjusting the demand values for spare parts in response to a change in process parts requirements discontinuing use of a part, and

wherein calculating a forecast demand comprises adjusting the forecast demand so as to run out inventory of the discontinued part.

17. The method of claim 14,

further comprising adjusting the demand values in response to a change in process parts requirements adding a new part, and wherein calculating a forecast demand comprises adjusting the forecast demand so as to provide for an initial stocking level of the new part.

18. The method of claim 14, wherein identifying demand values comprises using data associated with an enterprise resource planning computer system.

19. A method for managing enterprise-wide component inventory, comprising the steps of:

a. monitoring at least one identification device associated with a component, the component comprising a spare part or tool used in support of a manufacturing process;

b. determining a physical location of the component in response to the monitoring; and

c. adjusting inventory data for the component based upon the location of the component.

20. The method of claim 19, wherein monitoring includes scanning an RFID tag associated with a component that is in use in a manufacturing process.

21. The method of claim 19, wherein monitoring includes scanning RFID tags associated with a plurality of stored components.

22. A method for managing enterprise-wide component inventory, comprising the steps of:

a. identifying a plurality of components, each comprising a part or tool used in support of at least one manufacturing process;

b. maintaining warranty data for each component;

c. evaluating the status of each based on component data, including the history of the component and the warranty data; and

d. providing for repair of a component in accordance with the warranty data for the component.

23. The method of claim 22, wherein identifying includes monitoring at least one identification device associated with the component.

24. The method of claim 23, wherein the identification device comprises a smart tag emitting a radio frequency signal, and identifying comprises receiving, from a scanning device, the emitted radio frequency signal.

25. The method of claim 22, wherein providing for repair includes generating repair request documents and shipping documents for sending the component to a repair service provider when warranty coverage is available.