Industrial Engineering Methodology Applied to Spare Parts Control in an Automotive Parts Manufacturing Company

Abstract

This study outlines a series of activities aimed at establishing a methodology within the spare parts and tools warehouse of an automotive parts company engaged in injection, painting, and chroming processes. The objective is to exercise control over all components, providing maintenance with spare parts and tools upon request at minimum cost, while achieving efficient equipment and machinery upkeep. This, in turn, bolsters the company's production process. Various Industrial Engineering techniques were applied, including the 5S approach, which enabled the creation of a comprehensive spare parts inventory, complete with planned material requirements and a master purchasing plan. Historical statistical data were utilized to forecast future spare parts demand, achieving meticulous control. Inventory management methods, such as physical inventory checks, the Just-In-Time (JIT) system for maintaining low inventory levels, and the FIFO (First-In-First-Out) method for proper part rotation and obsolescence avoidance, were incorporated. Additionally, an ABC classification was used to prioritize and identify costlier items in the list. The Break-Even Point economic method was employed to determine the investment recovery timeline. The ISO 9001-2015 methodology was implemented to uphold attained standards, along with continuous improvement methodologies to further optimize processes day by day. Results are illustrated through graphs comparing project inception conditions to outcomes, including a reduction in spare parts from 2649 to 1661, a decrease in personnel from 10 to 7 employees, and near elimination of daily critical materials from an average of 10 to nearly zero. These accomplishments showcase the effectiveness of the implemented methodologies and their positive impact on the company's operational efficiency.