Introduction

The time coverage of spare parts and consumables is a very interesting topic in regards to the module of Inventory levels, supply and requisitions. The coverage allows us to know, and graphically visualize, the approximate time in days in which we will have stock of a certain spare part or consumable.

Many times simply knowing the amount of stock we have of a certain spare part does not tell us if said stock is enough or not to cover a certain period of time. However, seeing the stocks on time, it allows us to not worry about the quantities and rather to worry if the quantities we have are enough to cover the next 30 days, 60 days, 90 days, etc. If we know that all spare parts are covered for at least the next 30 days, and we are monitoring it, we will be calm and unconcerned about having to make emergency orders.

Calculation methods for coverage

Coverage can be calculated in 2 ways:

1. Establishing the average rotation that the spare or consumable has on a daily basis, that is, establishing the average daily consumption of the spare or consumable.

In this case, the coverage is calculated dividing the stocks by the rotation and gives us the days that these stocks will last.

2. Based on the flow of resources for scheduled maintenance in the MP Maintenance Management program. To use this method, it is very important to previously assign the resources that are used to carry out each of the equipment maintenance activities. (for more information, consult Allocation of resources to equipment and maintenance activities)

As a requirement also, the flow of resources must be continuously calculated. This flow of resources examines in the PM Maintenance Management program all the maintenance activities scheduled for the equipment, and in this way, it is possible to know the amount of each resource that is scheduled to be used for each day.

Which method of calculation for coverage should be used?

Calculation of coverage based on turnover. This way of calculating coverage is useful when:

  • There is a constant consumption of the spare or consumable.
  • No resources have been allocated to equipment maintenance activities in the PM Maintenance Management program.

Calculation of coverage based on the flow of resources. This way of calculating coverage is useful when:

  • There is no constant consumption of the spare or consumable
  • Resources have been allocated to equipment maintenance activities in the MP Maintenance Management program

For those cases where the consumption of the spare part is not constant (or in other words, it is sporadic) and the spare part is not assigned to any maintenance activity in any equipment, it is advisable in these cases not to use any calculation method to avoid bad interpretations.

Rotation editing for coverage calculation

The rotation of spare parts and consumables can be specified from different modules in the Parts Inventory.

Inventory levels and procurement time can be specified from different modules in the Parts Inventory.

1. From the submenu in the Inventory, Supply and Requisition Levels module

2. From the submenu in the Spares and consumables module

3. From the submenu in the Warehouses module

You may have previously chosen a single part, or a selection of parts.

When the screen is presented, you must click the edit button on the toolbar.

Calculation of rotation based on exit movements

A practical way to calculate the rotation of a spare part or consumable is by analyzing the output movements that said spare part has had. The Parts Inventory has a utility that allows us to easily calculate these values.

On the screen where the summary of inventory levels, procurement time, turnover and others is displayed, click on the button Calculate turnover and levels based on criteria.

Select the months you want to cover to analyze the spare parts, since, depending on the number of months chosen, the value of the rotation may vary.

We recommend calculating and using the rotation method to calculate coverage as long as the consumption of the consumable is more or less uniform. Otherwise it is advisable to leave this value at 0 (zero) and use another calculation method.

Optimal calculation of inventory levels based on turnover

When we have their specified rotation for spare parts, when we edit the minimum, optimal and maximum levels, the coverage appears on the right side to give us an idea of ​​the days that we would have covered in each case.

A practical way to calculate inventory levels is by using the rotation of each of the spare parts or consumables. The Parts Inventory has a utility that allows us to easily calculate these values.

On the screen where the summary of inventory levels, procurement time, turnover and others is displayed, click on the button Calculate turnover and levels based on criteria.

Here we have the option of calculating our levels depending on how many days we want to cover to have stocks and not have to be making purchases continuously. This value is calculated simply by dividing the days that we want to cover by the rotation, and that will calculate the appropriate stock value for each spare part.

Another way to calculate our levels is based on the procurement time of each spare part. As we said before, it is always recommended that the minimum level is greater than the procurement time for each product. In this way we will avoid running out of stock.

In each case, select the days you want for each level and that's it.

The calculation criteria may be different for each part or family of parts. For this reason, a group of spare parts can be previously selected and a criterion used. Then select another group of spare parts and use other criteria.

Generation of the flow of resources for the calculation of coverage

Another way to calculate the time coverage of our inventory is through the flow of resources. The resource flow examines in the PM Maintenance Management program all the maintenance activities scheduled for the equipment, and in this way, it is possible to know the amount of each resource that is scheduled to be used for each day. This method is useful when resources are adequately assigned to maintenance activities, since the proper calculation of future spare parts requirements will depend on it.

To calculate a flow of resources you must click on the button Generate resource flow from the submenu and then click on the button Generate resource flow.

The Parts Inventory analyzes all warehouses and their respective linked maintenance databases. If you want to consult the information of what was calculated, you can consult it through the button Check resource flow.

It is very important to be continually calculating this flow, as the information varies over time depending on everything that has been updated in the MP Maintenance Management program. For this, the window shows us the date of when the last calculation was made, as well as the program will notify us when it is convenient to recalculate the flow.

Take into account that the more often we are recalculating the flow of resources, the more accurate the schedule will be and the more accurate the coverage estimate will be.

Understanding the coverage schedule

Here's how to interpret the coverage schedule.

Green color range: It is the range, starting today, in which our stocks will be above the minimum level.

Yellow color range: it is the range, starting today, in which our stocks will be below the minimum level.

Burnt red (small) mark: indicates the point at which we will arrive at the time of procurement of the spare part. This point is critical since, after this point, any order we make after that date will not reach us in time and we will most likely run out of stock.

Brand (large) bright red: it is the day when our stocks will become 0 (zero).

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