Optimization of Spare Parts with Accurate Data

Challenge: 

Identifying Variant Reduction And Spare Parts Management 

Amazon operates a sizable pharmaceutical fulfillment facility with over 130 installed gearmotors but lacked a clear and standardized way to align equipment data with spare parts inventory. The reliance on internal part numbers without a clear link to actual equipment specifications led to confusion, wasted time, and an increased risk in spare part ordering, creating several major hurdles. Operational setbacks and challenges included:

• Identical units assigned different internal part numbers

• Multiple variations performing the same function, with no clear alignment between installed and spare units

• Potential to purchase incorrect replacements

Results:

Standardized Data That Reduced Variants And Simplified Part Numbers

Across three facilities, SEW-EURODRIVE identified approximately 28 apparent gearmotor variants and consolidated them into 13 standardized variants, a reduction of about 54%. The analysis also identified six stocked spare variants that were not used in production and could be removed, resulting in even more space becoming avaliable throughout the facility. Key outcomes included:

• Standardized spare parts and reduced variants with accurate internal part numbers
• Eliminated duplication and conflicting records
• Reduced ordering errors and risk of incorrect parts
• Scalable approach across multiple facilities
• Less storage space needed for variants led to more plant optimization