| ABB Full Service® Implementation Guide |__ ABB Service i Rowers cate Page | Annex 11-1: Spare parts codification grid Aprit 2000 1/16 Table of content 1. DESIGNATION AND CODIFICATION OF SPARE PARTS... LT MAIN OBIECTIVES nm sas 12 THE ABB ISV CopmcaTion System... 2. STEPS TO IMPLEMENT THE CODIFICATION SYSTEM. 2.1 ESTABLISH A CODIFICATION TEAM... 22 CLASSIFY MAINTENANCE SPARES... 23. DEFINE THE "ROOT FUNCTIONS" FoR STAN 24 — DeRNe CLASSES AND FAMILIES... 25 DERNE SUp-FAMILIES WITHIN TH: FaLaLies 26 DERINE Grours AND SUB-GROUPS.. 27 CODIFY THE VARIANTS vo onsnsome Baris AND CONSUMABLES. 3. EXAMPLES OF THE CODIFICATION OF STANDARD PARTS AND CONSUMABLES. 3.1 CODIFICATION OF A StANDARD PART. 32 CoDmCATION OF A CONSUMABLE. thekiew | CH Ot™ABs ABE Fu: | Gecurent Aelase cats Page | Annes 11-1: Spare parte codtdoation grid ‘pri 2000 erie ‘The junction of spare parts management is to anticipate, at all imes, the factory's maintenance needs as regards: consumables and current maintenance items, standard parts ané spate parts spectic 10 machines. To achieve this objective it Is important to have @ proper cesignation ane codiication system. ‘The imperence ct good spare parts management is increasing, being a factor eirecty responsible for cutting costs and increasing profitability. For example, im some incusties, the purchase costs of material and spares for maintenance can vary between 3 and 1096 et preducton cost ‘The procecure for standard parts and consumables will usually be the same, independent of the type of industrial actvty, the number of items, the existence or non-existence of a computerized system, and other tactors. The major cifference woul ba evidert n the types of specific parts as defined by the activity of each company. 1. Designation and codification of spare parts 1.1 Main Objectives Without a uniterm and common language, itis impossible 10 manage spare parts and stores for diferent production areas. Its therefore vital to set up one single coatfication and designation system for spare pars. A codification system has to meet the following requirements: ‘+ acode number must correspond with one item only; ‘+ an item must correspond with one code number only; ‘+ acode number must be fixed. Changing numbers causes confusion; ‘+ the code number must be logical, Le. itis glven according to @ codification grid which takes into account the main characteristics ofthe item which has fo be coded. Correct designation is indispensable in order to: ‘+ avoid stocking identical parts under different names in different plaoes in the store, and consequently avcid “false” stock-outs (where one sieck item is cut of stock while the same part with another designation is avaliable in sufficient quantity); + avoid adcitional administrative workloads and costs when standard paris are filed under various designations (generally supplier's designations); ‘+ speak the same language among users, purchesers and suppliers; ‘+ allow the supply of standard pans trom any number of suppliers and not from just one suppier. 1.2 The ABB ISV Codification System ‘The ABB Service Spare Paris Codification System is an &-cigh codification system. ‘The 8-digit codification system allows ABS to classify a very large number of items, for very large stores (up to 250.000 different toms), ‘The code is made up of two distinct pans: + The frst part covers the "main characteristics and functions" of the item. This part of the code consists of 5 digits, and represents a sorting process which divides all the spares into 9 classes (from 1 to 9) and then subdivides each class into families, sub- familias, groups anc sub-groups. y§88 Service Worldwide pros,’] ABB Full Service® Implementation Guide | ABB Service Falense cate Page Annex 11-1: Spare parts codification grid April 2000 3/18 + Once each class has been subdivided itis necessary to add some form of serial numbering system, which defines the different variants (dimensions, capacity, etc...) between items in the same sub-group. ‘This serial numbering system forms the second part of the code. In the ABB ISV codification system, 3 digits are reserved for this part of the code, covering up to 999 variants for any individual sub-group: CHARACTERISTICS & EUNCTIONS, VARIANTS aves cate Fase] | Annex 1-42 Spare parts codification gi April 2000 1/16 | BASE OIL. VISCOSITY / 40°C: < 500 mm/s (SUB-GROUP: 0) BEARING GREASE, BASE OIL. VISC./40°C: 220mm¥s_ (SERIAL NUMBER:005) BASE FLUID MINERAL OIL, OPER, TEMP. RANGE °C: (-30 +140) Wiat 8969 CMSenioe Worcwide prmden reg Ge 10 T¥L3M