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© Systecon AB 2010 Dimensioning of optimal spare parts stock in an operational dynamic situation Case: Swedish airforce reconnaissance POD (SPK39) Younes Lousseief, Systecon AB
© Systecon AB 2010 Summary How to dimension a cost efficient stock of spare parts when having large variations in system utilisation? Case study: Modular reconnaissance POD for JAS39 Gripen (SPK39) But first, some theory...
© Systecon AB 2010 Support Organization Stock levels Repair costs Time to repair Order costs Transportation time & cost Warehousing costs etc. Product Structure Item/Component prices Failure/exchange rate (MTBF) Repair / Discard decision Criticality Redundancies etc. Systems usage Number of systems Utilization Operational profile etc. Cost Efficiency System Approach
© Systecon AB 2010 WS DEPOT 10 sys (0.05)3 sys (0.02)4 sys (0.10)11 sys (0.05) Repair System Approach Right stock at the right place
© Systecon AB 2010 WS DEPOT 10 sys (0.05)3 sys (0.02)4 sys (0.10)11 sys (0.05) System Approach LORA – Level Of Repair Analysis Should I perform item repair and, if so, where? ? ? ? Repair?Or Discard?
© Systecon AB 2010 System utilisation Utilisation as f(t) Time 0.80 0.10 UTILF Avg = 0.158 Utilisation as f(t) Time 0.80 0.10 UTILF Avg = 0.742 Utilisation as f(t) Time 0.80 0.10 UTILF Avg = 0.450 48 weeks4 weeks 44 weeks 24 weeks 48 weeks Operational profile Average utilisation
© Systecon AB 2010 High system utilisation +Less system down time ?Have I overinvested in spares compared to my operational requirements? Utilisation (average) Time High +Less investment in spares ?Is my stock sufficient to keep me up and running during the peak periods? Utilisation (average) Time Low Low system utilisation
© Systecon AB 2010 System utilisation vs item repair TAT Utilisation as f(t) Time High Low TAT Steady state reached during peak period Results for the peak period are trustworthy UTILF = High and low. Compare! Utilisation as f(t) Time High Low TAT Steady state not reached during peak period (neither in low period) The results need to be further analyzed with respect to time Can next peak period be met with the same system performance? UTILF = High? Low? Average?
© Systecon AB 2010 WS DEPOT 10 sys (0.05)3 sys (0.02)4 sys (0.10)11 sys (0.05) Cost/Efficiency curve Steady-state Analythical tool Average situation
© Systecon AB 2010 Cost/Efficiency curve Monte Carlo simulation Operational profile in time Mission based results
© Systecon AB 2010 Case study: Modular Reconnaissance Pod - Sweden CASE MRPS
© Systecon AB 2010 Material Break Down Structure CASE MRPS MRPS – Modular Reconnaisssance Pod Capsule Electrical System DMM -Memory module Sensor... RMS – Record management system
© Systecon AB 2010 OEM*OEM B-Level Blekinge Air Force Wing Norrbotten Air Force Wing Support organisation CASE MRPS *OEM=Original Equipment Manufacturer
© Systecon AB 2010 Operational organisation CASE MRPS International mission Longer supply chain Higher utilisation requirements Blekinge Air Force Wing International mission B-Level Norrbotten Air Force Wing
© Systecon AB 2010 Required maintenance resources MRPS – Modular Reconnaisssance Pod Capsule Electrical System DMM -Memory module Sensor... RMS – Record management system MASST CASE MRPS Comm Box ATF test GSE Locate the faulty LRU Locate the faulty SRU RESOURCE ($)
© Systecon AB 2010 LORA: 4 different Maintenance concepts CASE MRPS OEM B-Level Blekinge Air Force Wing Norrbotten Air Force Wing OEM B-Level Blekinge Air Force Wing Norrbotten Air Force Wing OEM B-Level Blekinge Air Force Wing Norrbotten Air Force Wing + Short Turn-around-Time - Large resource investment costs - Longer Turn-around-Time +/- Less resource investment costs - Longer Turn-around-Time + No resource investment costs...or discard items instead of repair?
© Systecon AB 2010 Operational profile CASE MRPS Blekinge Air Force Wing International mission Norrbotten Air Force Wing Low utilisation High utilisation A x B x C x
© Systecon AB 2010 System Utilisation Org Review Set of optimal Solutions (stock & resources) Optimisation Resources Spare part assortment LORA results Yes No Chosen Solution (stock & TAT) Modif. ? Modify the model Input data OPUS10 spare part optimization and LORA analysis CASE MRPS
© Systecon AB 2010 Peak periodsMission success Overinvestment OPUS10 Cost/Efficiency curve Steady state CASE MRPS
© Systecon AB 2010 System Utilisation Org Review Set of optimal Solutions (stock & resources) Optimisation Resources Spare part assortment LORA results Yes No Simulation Chosen Solution (stock & TAT) Variations in time Mission start & success rates Modif. ? Ok ? Select another spare part and resource solution Modify the model No Detailed Op. profile Input data Result Yes SIMLOX analysis CASE MRPS
© Systecon AB 2010 80% CASE MRPS Result analysis 1 Mission Start RateMission Success rate 95.8%93.4% Stock Repair strategy
© Systecon AB 2010 80% CASE MRPS Mission Start RateMission Success rate 88.1%86.4% Result analysis 2 Stock Repair strategy
© Systecon AB 2010 80% CASE MRPS Mission Start FractionMission Success Fraction 83.9%80.4% Result analysis 3 Stock Repair strategy
© Systecon AB 2010 CASE MRPS Steady state result Steady state reached Period of interest
© Systecon AB 2010 Conclusions Variations in utilisation with respect to time calls for detailed analysis in time When having cyclic operational profile, measure the performance when reaching steady state It is important to perform during the periods of high utilisation since they tend to be more crucial Moreover Satisfactory system availability is not enough when having a mission based operational profile
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