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Saving Millions on Reuse

Quantifying the Value of Parts and Family Classification

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Say a manufacturer introduces 10,000 parts per year at approximately $5k per part. Even a 2% improvement in part reuse could net the manufacturer millions of dollars in savings! So, why aren’t more manufacturers focused on organizing and classifying their parts to achieve better reuse? How do you calculate the real costs of introducing a new part and maintaining it over the life of a product? And what is the best way to avoid part duplication?

The Lifetime of a Part Across the Value Chain

The lifetime value of a part should take into consideration far more than just the cost of its initial creation. The example below outlines the various teams that are often involved in a part lifecycle as it progresses from project to production and aftermarket phases.



product-development
 

Product Maintenance
Quality investigations, designing, dimensioning, test, PDM administration etc.

 
 
 
product-development 

Suppliers
Procurements & visits

Process and quality assurance at the supplier
Annual cost negotiations

 
 
 
operations

Material Handling
Set up, forecasting & ordering
Quality assurance Administration

Internal material handling
logistics, storage, packaging, kittling preparations
Assembly flow
Sequencing, material control

 
 
 

aftermarket

Spare parts Engineering
Creating & maintaining

Suppliers
Procurement & purchasing

 

System administration
Stock taking

Storage
Warehouse, inventory & scrapping

Logistics

3 YEARS
Project phase

5 YEARS
Production phase

15 YEARS
Aftermarket Phase