10SOPs For MRO StoresStep 2 – OrganizeFor the next step, the parts are organized generically by type. That means that all bearings are storedin one place, all cylinders in one place, all circuit boards in one place, all drive belts in one place, andso on. When placed in their storage fixture, the parts are sorted by size, smallest to largest.The machine or process-specific parts are organized and stored together for obvious reasons.General consumables, safety items, small tools, and office supplies are consolidated and organized,the latter two most frequently stored in lockable cabinets. Organizing the parts has built-in benefits:• Elimination of the need for costly storeroom remodeling, or new construction• Maximizes the effective use of existing space through efficient design and setup• Sorts parts generically and by specific machine use, which expedites location and retrieval, andresults in shorter equipment downtime• Assists with accurate physical inventories and cycle counts• Eliminates overstock, out-of-stock, or is-it-stocked problems• Frees up storage fixtures and storage areas for other uses• Enhances part and tool security• Reduces storeroom trafficThe storeroom now looks sharp and has a worldclass appearance. Another GIANT STEP towardsbecoming Reliable is taken.Step 3 – AutomateThe plant Maintenance Department should have an operational and functional CMMS in place. CMMS(Computerized Maintenance Management Systems) systems were introduced to desktop computersin the mid- 1980’s. A well-run, efficient, maintenance-oriented plant uses one, and the CMMS has abar-code-capable inventory module capable of handling and processing all the maintenance-relatedMRO-parts tracking functions. That module must be populated, complete, and kept up-to-date.After the locations have been clearly marked, a comprehensive, hands-on physical inventory isconducted. This includes the part number, a noun-first description, other descriptive elements, parttype, location, quantity-on-hand, vendor and cost information and special notes. Once completedand entered into the CMMS, inventory bar-code labels for parts are produced and applied.Bar-coding technology makes part and tool checkout easier, quicker and more accurate, allowsphysical inventories and cycle counts to be conducted more efficiently and accurately, and enablesthe storeroom clerk to manage stores effectively on a day-to-day basis.Forward March !The storeroom is now well on its way to meeting Lean and Reliable standards. As these rulesand steps are implemented, the day-to-day, routine activities of the storeroom start being practiced.Those routines are listed in Part 2 of this article. The end result is that the entire MRO-parts operationis both Lean and Reliable because the required parts are in house, they are on hand in sufficient yetminimum quantities, and they can be located and retrieved quickly when needed. The reordering,purchasing, receiving and restocking functions are accurate, efficient, timely and cost effective.Hence, the plant remains productive, profitable and competitive in a global-market economy.Part 2Day-To-Day OperationsIn Part 2 we will examine the day-to-day practices and procedures that must become routine practicein order to keep the storeroom in a Lean and Reliable operating condition.Unscheduled machine downtime has been replaced with CMMS-aided (Computerized MaintenanceManagement System) maintenance planning, predictive and preventive maintenance scheduling,<strong>AMMJ</strong> 20th ANNIVERSARY YEAR
SOPs For MRO Stores11Reliability Centered (RCM) and Total Productive Maintenance (TPM) practices, and manufacturing-friendlymaintenance work. These Best Practice maintenance activities require that MRO-parts storerooms consistentlymaintain an efficient, highly organized, and automated environment to support them.In order to do that, MRO storerooms need a working and structured system of practices. Their implementationcan be phased in during the cleanup, consolidating and organizing project listed in the earlier sections. AnMRO-parts storeroom should operate like a store: clean, organized, labeled, well stocked, and well run. Thereis a place for everything, and everything is in its place. The owner controls the cash flow.Support from all levels of management is crucial. Good leadership, cooperation, and support among the variouslevels of plant management achieve remarkable results and improve profit margins. When this support is inplace, it promotes an efficient, effective, and successful maintenance stores operation.These daily operating procedures are discussed below.A. SecurityIn order to maintain and ensure that parts are on hand and available when needed, they must be controlled.Control is the lynchpin that determines whether a storeroom operates on a stable platform, or on an unstabletrap door that collapses unexpectedly.Every retail business exercises some form of control over its goods. Nothing leaves the premises unaccounted for.Safeguards are in place to protect the owner’s investment. Why then are storerooms that support maintenanceactivities, which support a plant’s productive enterprises, which support any number of workers, consideredany differently? In too many places, the MRO-parts storeroom operates like an unmanned convenience store.Does yours?MRO-parts storerooms should be walled (or fenced) off from the areas around them. The walls should run tothe ceiling, or be high enough to defeat entry by ladders or other means. Storerooms should have lockablegates and doors, and have entry restricted to as few as possible. Door locks can be programmed to use