An investigation on inefficiencies in spare part management processes in South African Power Plants

Abstract

Inefficiencies in spare parts management can, and do, have great repercussions for the execution of maintenance in Eskom power stations. Despite this, the sub-processes of spare parts management in power stations had not yet been subjected to rigorous analysis to identify inefficiencies. Consequently, the purpose of this research was to establish the inefficiencies that exist in the management of spare parts in South African power stations, and also to determine the causes of the inefficiencies. All this was done with the intent of recommending a solution to improve spare parts management. It was for this reason that this research was conducted in 13 Eskom coal-fired power stations in South Africa. The first phase of the research was concerned with uncovering and documenting the spare parts management model presently used in Eskom. The second phase included the use of a modified process failure mode and effect analysis (PFMEA) and the Delphi method to identify inefficiencies, their sources, and their significance. The research found that the inefficiencies included unsuitable maintenance and inventory management strategies, as a result of inadequate analysis of plant history. Furthermore, the study established that inadequate analysis of history was a result of poor maintenance records, incompetence, and the lack of access to computerised maintenance management systems (CMMSs). With the inefficiencies and their causes identified, the third phase of the research was then devoted to developing a methodology for improving spare parts management. This led to the development of a framework for improving spare parts management practices in power stations. The framework was validated and verified through a Delphi process. This framework was then recommended for adoption in an Eskom standard procedure for improving spare parts management practices. The research was thus successful in recommending a solution to improve the operational effectiveness and efficiency of spare parts management in South African power stations.