A spare-parts list that actually shortens downtime
Stock by failure rate and lead time, not by unit price. The cheap part with a three-week indent is the expensive one.
Plants tend to stock what is cheap. The parts that cost you production are the ones with long indent times — a CPU, an HMI, a specific drive frame size.
Rank every critical machine part by lead time multiplied by the cost of an hour of downtime, then stock down that list until the budget runs out.
We build this list as part of a service contract and review it after every breakdown.
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