Blog

THE IMPORTANCE OF ORIGINAL SPARES

I recently visited the Southern Maharashtra Towns of Sangli and Kolhapur on a Business Visit .

Most of the visit was focused on Foundries and their problem with oil contamination.

However what i found more interesting was the customer’s persistent problems with hydraulic spares mainly.

Hydraulic Cylinders (Taiyo,Nambu,Kato,Yuken)

Hydraulic Pumps (Nachi)

Hydraulic Valves (Nachi , CKD , SMC and others )

Sangli and Kolhapur have been mainly identified as melting towns of Maharashtra . The availability of skilled manpower for the foundry jobs and the will of the Entrepreneurs  has got these towns some special credit. They actually know how this business is run and how to get the desired products from such a tedious process . The problem was seen in this region but is the same all over the industry .

Historically all the foundries were conventional with a lot of labour involved in the making , but with rapid growth in technology the industry modernised and a lot of machinery came into being . So from just hardworking people they developed the technical brilliance mindset and achieved a lot in terms of sophistication and machinery maintenance .

However the main problem that most of these industries face is procuring spares from international brands . From getting smaller spares such as Pressure Gauge or a Temperature sensor to getting Hydraulic Pumps and Cylinders . Unlike older machinery and mindset where the aggregates to the machinery used to keep working for a lifetime with no correlation to the number of cycles it has worked the modern day machinery require

1) Periodical Maintenance

 2) Replacements of Parts or the whole assembly after a specific number of cycles/strokes.

Periodic maintenance is never a problem as it is the part and parcel of the maintenance teams however the problem arises during the procurement of spares such as seal kits and other small items or during the process of replacement of the original part .

The only way to get spares is through the  Original Equipment Manufacturer (OEM) or try to search them locally or on the internet . The actual problem starts now . Let us be clear on 1 thing INTERNATIONAL BRANDS ARE COSTLY .(Why these spares become costly?? Who are the suppliers who can supply them?? What is the supply chain system in these spare?? I will write a seprate post on these aspects the motto of this post is a bit different .)

What i actually saw and was surprising was the maintenance people trying to change the brand of the spares and introduce new brands in the machinery . Let us agree that there is never a problem in changing brands till such time that you are using a reputed and more important PROVEN brand for the particular application . And the problem starts here .

I actually saw people trying to fit a square peg in a round hole . To save on the cost part there were numerous experiments being carried on to get the desired results. Though each experiment was falling flat and failing still educated, experienced people were not letting it go and trying different things. The only reason was to save on the high cost imported spares and aggregates . One of the main thing they were trying to replace were the original cylinders manufactured by Taiyo Japan with local home grown brands . Some were trying to replace the packing kits (Seal kits ) with local supplies available .

Image result for damaged hydraulic cylinders
BENT HYDRAULIC CYLINDERS

Related image
DAMAGED SEALS

Related image
CYLINDER BENDING UNDER PRESSURE
Image result for damaged hydraulic cylinders
DIFFERENT FAILURES IN CYLINDERS
Related image
SCORING MARKS
Related image
PACKING KIT CHANGE
Image result for damaged hydraulic cylinders
DAMAGED PACKING
Image result for damaged hydraulic cylinders
Image result for damaged hydraulic cylinders
SCORING OF RAM
Image result for damaged hydraulic cylinders
THIS CAN BE LIFE FATAL

Yes it is definitely possible to get cylinders manufactured on customize basis but then we have to be 100% sure that the manufacturer has the know how and expertise in the application he is dealing as well . It is not only important to just get some one manufacture a cylinder according to the dimensions available in the manual . But the pressure with standing capacity , the wear and tear in the environment it works the Material of composition is also equally important . And these factory are the main reason why branded spares are costly as the company is continuously investing in R&D to get the best possible product .Given below are some of the images of cylinder failures .

There are numerous problem which happen due to cheap replacements of hydraulic aggregates and a lot of Valuable time and energy is spent on trying alternative spares. However according to us any enterprise should focus on its core strength and here it should be manufacturing and completing the available targets of production. The job of the maintenance team is to see that the machinery is 100% available for production to the production team and regular maintenance is done on time . Also let us not discount that Companies all over the world spent a humongous amounts on development of new alloys and materials to be suitable for specific applications. Also the OEM who design a specific machinery have taken a lot of pains on selection of the aggregates and designing their circuits based on the same. One of the most important draw back seen while changing of brands in increased cycle time and slow response which again leads to catastrophic losses on the long run where you focus on saving peanuts and loose Pounds .

Yes it is obviously important to reduce your costs of replacement and spare procurement. But instead of doing such experiments there are ways to buy the same branded spares at a lesser price . We will dedicate a post to these methods in the coming few days.

For now we would like to inform the reader that it is 100% more reliable and cheap to buy the original spares if you consider the manpower and time spent on doing various cost reducing exercise .

We at Aquila Sales and Services are fully capable to fulfilling the needs of our customers for all their imported spares from Japan in a very cost effective way.

Note :- The post is the sole inteclectual property of Aquila Sales And Services headed by Mr.Ajit Naik and should not be reproduced or copied without the consent of the author .

What is it?

What is hydraulic system?

Hydraulics is mechanical function that operates through the force of liquid pressure. In hydraulics-based systems, mechanical movement is produced by contained, pumped liquid, typically through cylinders moving pistons. Hydraulics is a component mechatronics, which combines mechanical, electronics and software engineering in the designing and manufacturing of products and processes.

Simple hydraulic systems include aqueducts and irrigation systems that deliver water, using gravity to create water pressure. These systems essentially use water’s own properties to make it deliver itself. More complex hydraulics use a pump to pressurize liquids (typically oils), moving a piston through a cylinder as well as valves to control the flow of oil.

A log splitter is a single-piston hydraulic machine that uses a valve at either end of the cylinder that allows the pistons to be moved by the pressurized liquid, driving a wedge to force wood into smaller pieces and return to a home position. Force multiplication can be created by using a cylinder with a smaller diameter to push a larger piston in a larger cylinder. Often, there will be a number of pistons. Industrial equipment such as backhoes often use a number of cylinders to move different parts. Electronic controls are generally used for these more complicated setups on large, powerful equipment.

Hydraulics are similar to pneumatic systems in function. Both systems use fluids but, unlike pneumatics, hydraulics use liquids rather than gasses. Hydraulics systems are capable of greater pressures: up to 10000 pounds per square inch (psi) vs about 100 psi in pneumatics systems. This pressure is due to the incompressibility of liquids which enables greater power transfer with increased efficiency as energy is not lost to compression, except in the case where air gets into hydraulic lines. Fluids used in hydraulics may lubricate, cool and transmit power as well. Pneumatics, being less multifaceted, require oil lubrication separately, which can be messy with air pressure. Pneumatics are simpler in design and to control, safer (with less risk of fire) and more reliable, partially as the compressibility of the gas-absorbing shock can protect the mechanism.

How It’s Made demonstrates the use of hydraulics:

Right Hydraulic Spares

Right Hydraulic Spares for your valuable hydraulic machinery.

Most of us have at least one piece of machinery that uses hydraulics.

These are the machines that use fluids for power or to move.

Hydraulics are a part of just about every type of machinery, from cars to wind turbines.

We probably never notice them until they fail and the machine stops operating. Good maintenance is important when it comes to keeping hydraulics working. Hydraulic spares and repairs are a critical component of any business that uses hydraulic machinery. This is a very versatile type of system making it perfect for many different applications.

hydraulic spares in India
hydraulic spares in India

Hydraulics are systems where the fluid is used to swing, charge, turn, swivel or cause some other type of movement. The liquid runs through the hydraulic pumps, motors, cylinders, hoses, valves, and tubes. It condenses the molecules and creates pressure which powers the equipment. This pressure forces the machinery to move.

The most common use of hydraulics is as cylinders. These are usually found in motors and pumps. Anyone who has owned or operated hydraulic machinery has experienced cylinder repair or replacement. Maintaining and repairing hydraulic cylinders is often a significant part of an operating budget.

Maintenance is very important . . .

All machinery should undergo routine maintenance regularly and this helps ensure it continues to run and identifies when repairs or replacement of parts is necessary. Failure to keep hydraulic machinery in good repair can lead to failure or permanent damage. This will cost a lot more than taking the time to regularly check the machinery.

During the maintenance inspection, all aspects of the hydraulic system should be checked. It is recommended that a professional hydraulic maintenance specialist makes any repairs.

If there are any defects or damage discovered, it should be repaired immediately. This helps prevent small issues from becoming larger, more expensive ones. Keeping all hydraulic machinery in good repair is essentials otherwise, it will not operate efficiently and may even stop working altogether costing time, effort and money.

Call in the professionals always. . .

If repair work needs to be performed, it should be done by a trained hydraulic specialist. Just because someone can fix machinery, doesn’t mean they can fix hydraulic machinery. This is not an area for an amateur. It is best to hire a hydraulic specialist or if you have a lot of hydraulic machinery, to add a specialist to your maintenance staff. This will save you money in the long run since it can be very expensive to replace a piece of hydraulic machinery if it breaks down.

TIP: Keep spare parts on site or nearby . . .

If your business uses several pieces of hydraulic equipment, it is best to keep spare parts on hand at all times. It is a pretty quick fix if the parts are available and the mechanic knows what they are doing. When you have the inventory available, hydraulic spares and repairs can be completed without much machine downtime. If a part must be ordered, it may take several days to arrive, meaning the machine is out of service that entire time.

Using hydraulic machinery can certainly help a business. It is important to keep all hydraulic equipment well-maintained and to keep a good inventory of parts on hand for quick fixes.

 

The Right Parts at the Right Time: How to Manage Your Spare Parts Successfully

Do you have the right spares in stock when your equipment fails? Do you have too much of the wrong spares and need to write off part of your inventory each year? Spares are a requirement, yet a pain for many organizations. Why are they a pain? They typically are not managed with the level of rigor that all other materials groups are, but they need to be.

So where does one start when trying to get their spare parts program organized? Well, any spare parts program is made up of many different aspects. When all aspects are working together, the spare parts program ensures the right spares are available, in the right quantity, at the right time.

Why are spares needed?

Spare parts are kept on site typically for one of two reasons; unexpected failures, and poor work management practices. We can all agree that some failures are unpredictable and in those cases, we should have the right spare parts on hand to enable a quick repair.

In other cases, spare parts are stocked to perform routine Preventive Maintenance (PMs) and planned work. If a work management program is in place, and effective, one could argue that the need to stock extra parts can be eliminated.

So, the first step to fixing a spare part program is to ask yourself, why are we stocking this part? Is it because of an unexpected failure, or are we compensating for a poor work management program?

Having the right data

Once the reason for stocking the spares has been determined, the right data is needed to ensure that the stock levels are managed correctly, spend leveraged and that there are no duplicate parts in the storeroom. The right data can be broken down into a few specific types;

  • Master Data is what allows a spare part to be identified and specified. Master Data includes the description of the spare, which should follow a defined taxonomy, manufacturer, part number, class, sub-class and any attributes.
  • Procurement Data is the data that allows the spare part to be procured. Procurement data includes the price, lead time, and vendor.
  • Usage Data is the historical data that reflects how often the part has been used in the past and what equipment the parts below to.

All of this data is critical to the management of the spare parts and should be controlled by a governance process to ensure it is accurate and consistent.

Organizing a storeroom

When you walk into your storeroom, what do you think of? A junk drawer in the kitchen or an auto parts store? The storeroom should be organized in a way that allows easy access to the commonly used parts (think nuts, bolts, Loctite, etc.) and controls access to the more important or expensive parts.

Also, the parts are organized by the class (or type) of parts. You don’t have headlights for a car in section and headlights for a truck in another. All lights are in the same section. So why are storerooms constantly organized by machine and not the type of part? This makes parts hard to find and can lead to duplicate parts.

So, when setting up your storeroom, think of your local auto parts storeroom and model your storeroom after the store.

Calculating the right level of spares

Most stocking levels are determined by the craftsman thinking he will need 3 to do a job, so he asks to have six stocked. The storeroom staff then double that min to arrive at a max. As you can imagine, this leads to an extremely high level of extra or unnecessary stock in the storeroom.

The right way to calculate the level of spares is to use Data (see above). The min, max, safety stock and criticality can be calculated with a few basic formulas;

– Minimum Stock Quantity (Min) = (usage per year / 365) x Lead time
– Maximum Stock Quantity (Max) = Minimum quantity + Economic order quantity (EOQ)

– Economic Order Quantity = √(2DS/H)

D = Usage per year
S = Ordering cost per order
H = Inventory carrying cost

– Safety Stock = (maximum lead time – normal lead time) x normal consumption rate

– Normal consumption rate = expected annual usage / 365

– Criticality can be determined by using a basic risk matrix;

1 – 2 = Do not stock
3 – 12 = Setup stock
15 – 25 = Setup critical stock

Enterprise-Maintenace-Spare-Parts-Criticality.jpg

 

There are much more advanced formulas and techniques available, but if most organizations use this basic approach, the savings realized across the storeroom would be tremendous. Data-driven decision-making trumps gut feel any day.

Shelf life management & maintenance of spares

Spare parts, like most other materials, have a limited shelf life. If that shelf life is exceeded and the parts are used, it has the potential to impact reliability. Take a V-belt for example. If a V-belt is hung up on a nail and left there for two years in the sunlight, the V-belt will develop a weak spot from hanging on the nail and the rubber will degrade due to the UV light. If this belt is installed, how long will it last?

Spare parts also require maintenance. Yes, you read that right. Take for example large motors, should have their shafts rotated on a regular basis to prevent flat spots from developing on the bearings. If this is not done, the larger motors can be installed with a defect and lead to a premature failure.

The best way to make sure that your spares are preserved in the best possible way is to follow the manufacturer’s recommendations.  Without any manufacturer’s recommendations, the storeroom can follow these basic rules of thumb;

  • Keep rubber products out of direct sunlight
  • Don’t hang belts on a peg or nail, lay them down
  • Rotate large motors shafts 1-1/4 turns every 3-6 months
  • Use a first-in, first-out approach with stock
  • Bearings have a shelf life of 5-8 years (after that the lubricant will dry out)
  • Keep the spares in their original packaging to prevent contamination

Keeping spare parts in good condition is not difficult, it just requires a little bit of forethought.

Managing spares performance

“You Can’t Manage What You Don’t Measure,” and this is true in the storeroom as well. Do you know what your stock turns or stock-outs are? How much stock hasn’t moved in the past 18 months?

When looking at storeroom performance, there are any different aspects to consider, so if you are not currently measuring anything, pick a measure or two to focus on that area. For example, if the craftsmen are complaining that the storeroom never has the right parts, but there is a large amount of stock in the storeroom, consider looking at stock turns.

However, when picking the proper performance measures, be sure to select a balancing measure as well. If you choose to focus on stock turns to evaluate if you have the right stock, be sure to balance with stock-outs. This way the storeroom is still being managed in a way to deliver service.

Next steps

While the article above is not an in-depth step by step guide to transforming your storeroom, it should prompt you to think about what could be done differently in your storeroom. I encourage you to pick one of the topics above and think about what changes you can make.

Remember, to find success; you must first solve the problem, then achieve the implementation of the solution, and finally sustain winning results.

James Kovacevic

Link to original article – Click here

THE RISE OF JAPANESE MACHINES AND THE AVAILABILITY OF ORIGINAL SPARES

Japan entered a big way in India with the commencement of MARUTI – SUZUKI INDIA LTD . This was the company which gave India its first hatch back with a world class engineering . To maintain the high standards of engineering tolerances and quality most of the critical machines were imported from Japan.

Maruti also formed a large vendor base to cater to its requirements how ever at that time most of the vendors had to make a large investments in machinery to match with the standards of the Japanese car maker . And with the influx of these machines the Indian Industries was overflowing with machines made in Japan .Also with such a huge population of these machinery there was a large requirements of spares for these machines but this was where the bottle neck was … Most of the parts suppliers to the Japanese machine makers has minimum or no presence in India at all . So the Indian Industrialist had 2 options either to buy these spares are very high prices from the machine manufacturer itself or replace them with the locally available spares . And this story has remained the same till date.
However in the above scenario if you buy costly spares from the machine manufacturer its still better but if you try to change the spares with the locally available ones there is much to loose . Every machine builder has a special design for his hydraulic,pneumatic or electronic circuits which makes them stand apart from the other manufacturers and gives them their USP . If you try and change these critical components like Pumps , Sensors , Valves the machines will in some way or the other start to show the symptoms of slowing down . Most equipment just tend to increase the cycletime which is not good for the production targets of any company .

Some of the brands with form a integral parts of the Japanese make machines are Taiyo, Toyooki, NSK, Nachi, Mitsubishi, Yuken, Nagano, Ask, Himu, Toshiba, Toyoda, Kondo, Sugatsune, Dai-Ichi, Pilot, Nissei, CKD, SMC, Oriental, Mirai, Valcom, Denso, Janome, Yamaha, Panasonic, Yaskawa, Fuji, Kohzu, Horiuchi, Ryousei, Kobe, Urawa, Maxpull, Kyoritsu, Asahi, Aichi and many many more.

You might actually find it even to locate these companies even while using the best search engines , However we at AQUILA SALES AND SERVICES have established very good business relations with most of the companies in Japan . And hence can provide you any spare from the original manufacturer at the best price and lowest deliver time .
So next time you require something from Japan… Don’t forget to mail us or call us ……