What spare parts are needed for DC motor and motor automatic bearing press fitting machine and how to set up guarantee stock?
I. Spare parts list
1、Mechanical parts
l Press-fitting head and mold: These are the parts directly involved in bearing press-fitting, which are easy to be worn, deformed or damaged due to long-term use. Different specifications of bearings may require different press fitting heads and molds, which should be stocked according to the type of bearings often processed by the equipment.
l Guide rails and slides: Ensure that the press-fit parts of the press-fit machine can precisely perform linear movements. As they are subject to friction and wear during frequent movements, they are required as spare parts.
l Drive belts and chains (if any): Used to transmit power, they may slacken, wear out or even break after long-term use, so stock the right type according to the transmission method of the equipment.
l Bearings and bushings: There are many rotating parts in the equipment that need bearings to support them, while bushings can reduce the wear of the shaft. These parts may be damaged under high load operation and need to be kept in reserve.
l Seals: such as oil seals, seals, etc., used to prevent hydraulic oil, lubricating oil leakage, as well as to prevent dust and impurities into the internal equipment. They are wearing parts and need to be stocked in appropriate quantity.
2、Electrical parts
l Motor brushes (for brushed DC motors): brushes are the parts in the motor that contact with the commutator, wear and tear will affect the normal operation of the motor and need to be replaced regularly, and should be prepared for sufficient brush spare parts.
l Fuses and circuit breakers: In the event of an overload or short circuit in the circuit, the fuse will blow and the circuit breaker will trip to protect the equipment safeguard. These are common perishable electrical components that need to be spared.
l Relays and contactors: they are used to control the on-off of the circuit. Frequent actions may cause the contacts to wear out or stick, so a certain number of spares should be stocked.
l Sensors (e.g. pressure sensors, displacement sensors, etc.): Sensors are essential for precise control of the press-fitting process, and may fail due to factors such as the working environment, so spares are required to ensure that the equipment can be restored to operation in time.
l Wires and cables: Wires and cables in the equipment may be damaged due to aging, wear and tear, or accidental damage. Prepare wires and cables of different specifications for emergency repairs.
l Hydraulic and pneumatic pumps (if any): As the power source of a hydraulic or pneumatic system, a malfunction can paralyze the entire system. Although they are relatively durable, spares should be available to minimize downtime.
l Hydraulic cylinders and pneumatic cylinders (if any): these parts perform press-fit action directly. Conditions such as deterioration of seals or damage to the cylinder may occur and need to be kept in reserve.
l Hydraulic and pneumatic valves: they are used to control the flow direction, pressure and flow rate of hydraulic oil or gas, and are prone to clogging, spool wear and other malfunctions, so some commonly used valve parts should be prepared as spare parts.
l Filter elements and screens: used to filter impurities in hydraulic oil and gas to keep the system clean. They need to be replaced regularly, so keep a certain stock.
Second, to protect the inventory setup method
1, based on the frequency of use and failure rate of equipment
Statistics equipment in the past period of time (such as a year) the frequency of replacement of various components, combined with the operating time of the equipment, the amount of production tasks and other factors, to predict the number of possible failures of each component in the future period of time. For example, if a particular model of press fit head has been replaced 3 times in the past year, and the equipment is expected to operate for a similar amount of time and production volume in the coming year, then consider stocking 3 - 5 press fit heads of that model as a safeguard inventory.
For components with a high failure rate, increase the percentage of guaranteed stock. For example, the fuse, because it will fuse in the circuit failure, in order to avoid frequent procurement of downtime caused by waiting, the guaranteed stock can be set to 1.5 - 2 times the expected use of the quantity.
2, consider the procurement cycle and supply stability
Understand the procurement cycle of each spare part, including the supplier's production cycle, transportation time. For parts with a long procurement cycle, such as some special specifications of the sensor or customized molds, should increase the guaranteed inventory. For example, if the procurement lead time for a sensor is 3 months, then at least the quantity of that sensor needed to sustain 3 months of production should be stocked as a guaranteed inventory.
Evaluate the supply stability of the supplier, if the supplier is prone to stock-outs, delivery delays, etc., the guaranteed inventory should also be increased accordingly. You can reduce the supply risk by cooperating with multiple suppliers and signing priority supply agreements.
3, combined with the cost and importance
For expensive but not very easy to damage the components, such as hydraulic pumps, can be based on the importance of the equipment and the cost of downtime to weigh the number of guaranteed inventory. If the equipment downtime will lead to huge production losses, even if the hydraulic pump price is high, can be appropriate to reserve 1 - 2 as a guarantee stock.
For inexpensive components that are critical to the operation of the equipment, such as seals and small-size fuses, a relatively large amount of guaranteed stock can be maintained to ensure that the equipment can be repaired and restored to operation in a timely manner. At the same time, bulk purchase of these low-cost components may also receive certain price concessions.
4, set up a dynamic adjustment mechanism
Regularly (such as quarterly or semi-annually) review the operation of the equipment, the frequency of replacement of components, procurement cycle and the supplier's situation, according to the actual changes in the guaranteed inventory for dynamic adjustment. For example, if the failure rate of a component is reduced through equipment upgrades, or a more stable supplier is found to shorten the procurement cycle, the guaranteed inventory for that component can be appropriately reduced.
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