Spare Parts Management

This Business Scenario Map shows the overall process, from the time of the malfunction report to the processing of the task, from the viewpoint of spare part procurement. Each person involved in the process, from the asset operator to the procurement organization, via the maintenance engineer, has permanent access to potentially necessary spare parts and their availability. Instant information on whether or not all materials held in stock or to be procured are available for the desired time can be obtained using the ATP check in the maintenance task. The task processor receives an automatically generated log with detailed material-related information about possible shortages. This streamlined process saves time and money.

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Value Potentials	Business Benefits
Up to 100% exact determination of spare parts availability*	Asset Operator and Maintenance Engineer have access to spare parts and can always see the current stock
Up to 100% exact determination of earliest possible delivery date of spare parts to be procured externally*	ATP check at the time of task planning enables exact determination of reparation time and availability of asset after execution of task
Up to 50% less spare parts stock*	The decision to exchange or repair can be made immediately from point of view of spare parts availability
	Immediate availability of estimated material and procurement costs

Production Asset Operator

Maintenance Engineer

Spare Parts Manager

Release asset

Plan repair dates

Error is reported

Receive usage statistics

Cancel unnecessary parts

Complete repair

Plan tasks and complete availability check

Optimize usage of stock

Automatic re-procurement of parts

Issue material and post goods entry

Receive automatic reservation / purchase order

Source:
* Discussions with Customers

The value potentials shown in this table have been reported by selected SAP customers or independent third parties as referenced herein. However, there is no guarantee that such value potentials can be realized in any particular customer-specific business processes, and SAP does not make any representations and disclaims any liability as to the appropriateness of the referenced value potentials for any specific customer situation.
©SAP AG 2008

Business Benefits	Value Potentials
Extensive automation of procurement for highest quality and best price
Reduction of waiting times because of missing material or deliveries	Up to 80% reduction of backlog caused by missing material*
Optimization of material stock according to usage and availability on market	Improved stock turn rate for spare parts stock from 6 years to 1 year*


Spare Parts Management Optimal spares provisioning is a prerequisite for all types of maintenance tasks, such as inspections, preventive maintenance, and repairs. With the exception of preventive activities, spare parts for maintenance tasks are usually required at random intervals. Thus, the fast and secure coordination of the demand for spare parts with the supply of spare parts at the required time is an important factor for the punctual execution of the maintenance process. Missing materials are one of the most frequently cited reasons for the delay in completion of maintenance tasks. As spare parts for machinery are often very high quality, this problem cannot be solved simply by increased warehouse stock. This process illustrates how a maintenance planner can get an overview of potentially necessary parts and their availability, right from the moment a problem occurs. If a concrete maintenance task is planned in a further step, the system determines and logs the exact availability of the materials at the required time, regardless of whether the materials are in stock or must be procured externally. The replenishment lead time of the spare parts also becomes apparent from this process. If this is further in the future than is reasonable, the maintenance engineer can consider exchanging an asset instead of repairing it. Assets can also be managed in stock and considered in the same way as materials for planning purposes. The system issues reservations and purchase requisitions, which can be processed by the relevant departments in the spare part industry. Thus, all those involved, from production to purchasing and storage, via maintenance, have complete transparency about the material availability and the possible completion of the task. The planned material costs in the task are documented in the same way. The material withdrawals are documented by the system and form the basis of usage-controlled materials planning. With this process, material stocks of spare parts can be optimized to support maximum availability with minimum stocks. * = This business process is supported by Best Practices for SAP Business Suite. Best Practices for SAP Business Suite represent prepackaged business expertise in the form of methodology, documentation and reliable preconfiguration for SAP solutions. This helps you to start with a fully documented and reusable prototype for this scenario only days after you have installed the software. A prototype representing the results of a complete implementation project done up front and encapsulated in one single product that can rapidly turn into your productive solution. Best Practices for SAP Business Suite puts the power of SAP Business Suite in your hand.