1. Technical management of spare parts
The technical management of spare parts is the basis of spare parts management, which mainly includes: the collection, mapping and compilation of spare parts drawings; Design and compilation of basic data such as statistical cards and reserve quotas of various spare parts.
1. 1 standards and requirements
(1) Overall determination of spare parts quota.
(2) Complete the production and technical preparation of overhaul spare parts.
(3) Don't predict the model number of equipment (usually sizing equipment).
1.2. Check the contents
(1) Spot check;
(2) Check the equipment maintained in that year.
1.3. Check several assessment indicators of spare parts work.
(1) standards and requirements
① Spare parts supply rate:
The requirements for setting up equipment and supply rate are above 85%.
② Monthly turnover rate of reserve spare parts:
General requirements are greater than 30%; If it is lower than 30%, it is necessary to find out the reasons and take measures to eliminate the backlog.
(3) Spare parts sharing rate:
The general requirement is more than 70%.
(4) The percentage of spare parts reserve funds in the original value of fixed assets of the whole plant can be determined according to the characteristics of the industry, and it is generally appropriate to be within the range of 1% ~ 3%.
(2) Check the contents
① Spot check;
2 audit;
(3) check the original documents.
2. Planning and management of spare parts
The plan management of spare parts refers to the work from spare parts planning to spare parts warehousing, which mainly includes: self-made spare parts plan in 1 month, annual and batch plan of purchased parts, demand application and manufacturing plan of casting and forging blank parts, spare parts piecemeal procurement and processing plan, preparation and implementation of spare parts repair plan.
Spare parts planning management is a comprehensive spare parts management based on enterprise maintenance plan, technical measures, equipment renovation and other project plans. According to the length of the planning cycle, it can be divided into annual plan, quarterly plan and monthly plan. According to the content, it can be divided into demand plan, order plan, special spare parts plan for overhaul, special emergency spare parts plan and spare parts fund plan. According to the types and supply channels of spare parts, it can be divided into industrial and mining spare parts plan, special spare parts plan, purchased spare parts plan, self-made spare parts plan, auto spare parts plan, large-scale casting and forging plan and foreign spare parts order plan.
A complete and accurate spare parts plan is not only an integral part of the enterprise's production, technology and financial plan, but also an important condition for equipment maintenance to ensure the normal production of the enterprise.
(1) annual comprehensive plan
It is a comprehensive professional plan based on the annual production, technology and financial plan of the enterprise. Mainly includes the following contents:
2. 1 spare parts demand plan
Spare parts demand plan is the most basic plan, which reflects all the spare parts needed by each workshop and all kinds of equipment in one year, and is the basis for compiling other related spare parts plans. The main contents are:
2. 1. 1 spare parts for the maintenance and pre-repair of in-use equipment;
2. 1.2 spare parts required for technical transformation measures, safety and environmental protection measures and other projects;
Equipment modification requires 2. 1.3 spare parts;
2. 1.4 self-made replacement equipment needs spare parts.
2.2 Spare parts ordering plan
Spare parts ordering plan is based on spare parts demand plan.
2.3 Annual Overhaul Spare Parts Plan
The special spare parts plan for annual overhaul is a spare parts plan specially prepared for the annual factory-wide overhaul of enterprises, and it is a one-time special consumption plan.
Warehouse management of spare parts refers to the work from storage to delivery of spare parts, which mainly includes: inspection, maintenance, registration, loading and unloading of spare parts, sending and receiving of spare parts, cleaning and safety of warehouse, ordering point and inventory control, spare parts consumption, statistical analysis and control of capital occupation and turnover rate, and collection of spare parts quality information.
Warehouse management is an important part of spare parts management. Keeping the spare parts warehouse well is an important guarantee for spare parts supply. The storage and maintenance of spare parts must be strengthened to ensure timely supply with good quality and quantity. Reasonable storage, accelerate turnover and improve warehouse management level.
(A), warehouse settings
At present, there are two ways to set up spare parts warehouse in enterprises. First, large joint venture, two-level management, two-level database. That is, the company (general factory) has a general warehouse, which only manages general spare parts and industrial and mining accessories. Each factory (branch) shall set up a warehouse to manage all the special accessories of the factory (branch). There is no warehouse in the production workshop. Second, small and medium-sized enterprises, the implementation of first-level management, first-level database. There is no warehouse in the production workshop. There are many kinds of spare parts in an enterprise, and the technical performance and storage conditions are different, so the internal facilities of the warehouse must also adapt.
The basic requirements of the warehouse are as follows.
1, the warehouse location should be convenient for spare parts to enter, exit and transport, and convenient for production workshops to collect. Try to avoid the harm of corrosive gas, moisture, dust, radiant heat and other harmful substances.
2. Flood control and drainage should be considered in the warehouse to avoid water accumulation in the reservoir area. When the warehouse is built by the sea and the river, the elevation of the warehouse foundation must be higher than the highest level in history.
3. The water and electricity in the warehouse should be convenient. Water is an important condition for warehouse fire safety; Electricity is necessary for the power and lighting of spare parts transportation and loading and unloading mechanization.
4. The warehouse should be dustproof, heat-proof, frost-proof, moisture-proof and shockproof. It can not only be closed and isolated, but also achieve good ventilation.
5, outdoor open-air garage, the ground should have drainage slope and small ditch, should set up stow-wood or other alternative cushion.
(2) Inventory, profit and loss and profit and loss rate of spare parts in stock
Spare parts in stock must be counted once every six months to ensure that the accounts, cards, materials and funds of spare parts are unified. In case of shortage, surplus, damage, poor quality, non-conformity of specifications, etc. , should find out the reason, according to the profit and loss adjustment, scrap and other inventory. , reviewed by the equipment management department and reported to the Ministry of Commerce or the superior competent leader for approval.
Profit-loss ratio is an important quality index to evaluate warehouse storage. The higher the profit-loss ratio, the lower the storage quality. On the contrary, the storage quality is good.
The calculation formula of spare parts profit and loss rate is:
When calculating profit and loss, you can't break even to get the figure of net profit or net loss. Regardless of profit and loss, it should be submitted for approval according to the prescribed procedures, and the profit and loss and spare parts loss report should be filled in.
Inventory spare parts receiving and dispatching, balance report should be accurate, and timely report to the financial department. Send inventory information to spare parts personnel, orderers and planners in time through inventory and statistics, so as to take measures to maintain normal spare parts inventory level.
Fixed reserve principle
Fixed reserves must follow the principle of "fixing reserves by consumption". When formulating the reserve quota, a basic principle is that only vulnerable parts and general parts can be properly reserved. A piece of equipment should not be divided into several parts, but should be stored all together. General mechanical and electrical products; It belongs to the scope of material supply and can be purchased as planned in the market, such as hardware, plumbing parts and standard parts. ; The annual consumption of a single spare part is less than 0.5, which is easy to repair after being damaged, and has little impact on production, such as pump seats and various casings; The manufacturing is simple, the materials are common, and the workshop can solve it by itself, such as small shafts, small sleeves, flanges, bolts, etc. Spare parts without complete drawings.
3. Capital quota and quota reserve ratio
According to the reserve quota, calculate the reserve quota fund of a single spare part, that is, m = NR.
Where m is a single spare parts reserve fixed fund, RMB;
R refers to the planned unit price or actual unit price of a single spare part, yuan/piece;
N- single spare parts reserve quota, number of pieces.
For example, a certain type of pump contains a variety of spare parts. Add up the capital quota of various spare parts, and you can get the capital amount of this type of pump. Then add up all the spare parts of pumps in this enterprise and get the capital quota of this kind of industrial pumps. By analogy, the capital quota of air compressor, freezer, centrifuge and metal cutting machine tool is calculated. Adding up all kinds of funds, we can work out the funds needed for spare parts reserve of this enterprise, that is, m2 = σ NR.
Where m2 is the total amount of funds required for spare parts reserve of the enterprise, RMB;
N- single spare parts reserve quota, number of pieces;
R—— Planned unit price or actual unit price of a single spare part, RMB/piece.
The working capital occupied by fixed reserves is generally 2% ~ 4% of the original value of fixed assets of enterprise equipment. In order to promote spare parts management, the quota reserve rate should also be evaluated. Or the fixed reserve ratio should be above 90%, and strive to reach 100%. The above two algorithms can be used, but the number of assessment items can better reflect the actual situation than the number of assessment items.
4. Requirements and methods for opening an account
Establishing spare parts ledger is a necessary means of material management. It is the basic work of spare parts management to set up spare parts reserve account and balance account correctly and perfectly, and do daily accounting treatment carefully to ensure the consistency of accounts, cards, goods and funds.
The setting of spare parts ledger should be convenient for classified storage of spare parts, inspection of spare parts inventory quantity and capital occupation, and statistical accounting.
The account book can be compiled according to the number of "No.4" part (warehouse, shelf, floor and location), and the spare part number, spare part name, specification, model, drawing number, maximum reserve, minimum reserve and quota reserve of spare parts can be added, and marked at the top of the account page for reference.
All kinds of spare parts purchased with different funds should be accounted for separately. Spare parts belonging to production and operation, which are stored by production reserve fund, special overhaul fund and renovation fund (including equipment renewal, technical measures, safety measures and "three wastes" treatment, etc.). ) In principle, it should be earmarked and managed separately. When production spare parts are sometimes needed for capital construction, the allocation procedures must be handled in advance, and the accounts should not be confused.
Reduce the backlog
The backlog of spare parts not only fails to play its due role, but also occupies funds and warehouses, increases management workload and causes serious waste of manpower, material resources and financial resources. Especially non-standard spare parts, once accumulated, they may become "dead things". In order to reduce the backlog, we should do the following work.
Strengthen plan management. The reason for the backlog is generally poor planning and inaccurate quota. Therefore, enterprises should strictly control unplanned procurement and ordering.
It is necessary to arrange the overhaul interval reasonably. Equipment can neither be in disrepair nor be over-maintained.
Major accident spare parts reserve. Large and medium-sized chemical fertilizer plants implement unified fund-raising and warehousing, storage in sections and centralized use according to the ownership of similar production plants and similar models. This is a good method that other chemical enterprises can follow.
Strengthen spare parts management. The confusion of management work is also the cause of the backlog. Spare parts management of each enterprise should have a centralized department, which cannot be dispersed.
Strictly control the warehouse and implement the "three no warehousing" system. That is, unqualified products are not put into storage; Does not meet the requirements of the drawings; Those without contracts will not be put into storage.
Improve ideological understanding. All spare parts managers should pay equal attention to material and money, overcome the phenomenon that more is better, and do a good job in the management of spare parts and funds in the circulation process.