Material Planning and Inventory Control
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Powered by AIThe reorder process for consumables, such as filters and lubricants, is typically based on the average monthly use (AMU) and involves evaluating annual consumption and shelf-life considerations to determine optimal stock levels and reorder points . Conversely, the reorder for components, which can be repaired and them reused, involves basing the initial spare float on maintenance tools and demand data, with reorders linked to BER (Beyond Economical Repair) or scrap units, reflecting the longer lifecycle and complex planning needs for repairable or rotable items .
When setting re-order points for aviation consumables, factors to consider include the average monthly usage (AMU), annual consumption patterns, shelf-life of the products, supplier lead times, and the availability of the items in the market . These variables help determine the optimal quantities to maintain, ensuring continuous availability without overstocking, which is critical in managing inventory costs and avoiding expired stock .
National variance influences aircraft spare provisioning by necessitating adjustments in spare parts inventory and material planning according to domestic regulatory requirements and operational conditions . This helps ensure compliance with local aviation standards and accommodates the specificities of operational environments, which might differ significantly from those in other countries .
Rotable components, such as wheels and brakes, are parts that can be repeatedly repaired and reused over their lifecycle, making them long-term assets held on a firm’s books until they become surplus or are scrapped . In contrast, repairable parts, such as oxygen bottles and main DC power batteries, have a variable scrap rate between 0% and 100%, lasting until they are scrapped . Maintenance planning for rotables involves managing asset rotation and ensuring repair processes are efficient, whereas planning for repairables involves managing inventory to account for a potentially higher frequency of replacement and ensuring repair capabilities are readily available to meet demand .
Priority levels such as Critical Priority and Immediate Operational Requirement (IOR) impact aviation logistics by altering the urgency and costs of procurement processes. Critical Priority demands quick action to address requirements under concession that may affect aircraft operability, often leading to higher logistics costs due to expedited shipping and handling processes . IOR priorities, while less urgent than AOG or Critical Priority, still necessitate prompt procurement actions with defined follow-up periods to ensure operational needs are met within 15-30 days, affecting how supply chains allocate resources and manage schedules .
The RSPL aids airlines by providing a tailored document developed by manufacturers that incorporates part number, part name, budgetary price, spare parts class, essentiality code, phase provisioning, and mean time between unscheduled removals (MTBUR). This ensures operators have a strategic framework grounded on their fleet size, operating plan, and national variance, allowing for efficient allocation and stocking of necessary spares, ultimately optimizing maintenance schedules and reducing downtime .
Scheduling base maintenance presents challenges including longer downtime requirements for detailed inspections and substantial overhauls, as it involves extensive checking and servicing of aircraft structures and systems, which is not typically the case with line maintenance . Base maintenance, often conducted every 2-5 years as C-Checks or every 8-12 years as D-Checks, also demands significant resource allocation and coordination to manage aircraft availability . In contrast, line maintenance occurs frequently (before or after each flight) and involves routine, quick checks that require minimal downtime but must be consistently scheduled to maintain flight safety and readiness .
Data from Maintenance, Repair, and Overhaul (MRO) partnerships can enhance spares provisioning by providing insights into component failure rates, historical maintenance interventions, and best practice recommendations based on broader industry experiences . MRO expertise offers detailed operational data, effective troubleshooting techniques, and more accurate forecasting for spare parts needs, thereby improving maintenance efficiency and minimizing aircraft downtime .
Prioritizing Aircraft on Ground (AOG) orders is critical because these situations demand immediate attention to avoid extended downtime, which directly impacts operational schedules and airline revenue . An AOG situation signifies that an aircraft is grounded due to the unavailability of necessary parts, compelling swift logistics operations to procure and supply these parts, usually within 24 hours . Efficient management of AOG orders is essential for maintaining an airline's operational continuity and customer satisfaction by minimizing delays and cancellations .
Different maintenance checks, such as A-Check, C-Check, and D-Check, contribute to ensuring an aircraft's airworthiness and reliability by systematically inspecting and servicing aircraft components at scheduled intervals. A-Checks involve basic inspections and fluid checks after 4-6 months or every 800-1200 flight hours . C-Checks are more detailed and conducted every 2-5 years, including thorough structural and system inspections . D-Checks are the most extensive, occurring every 8-12 years and necessitating major overhauls and disassembly of aircraft systems . This layered approach ensures that potential failures are identified and addressed promptly, maintaining safety standards and operational readiness.
