DIRECTSPARE

Strengthening the industries’ competitive position by the development of a logistical and technological system for “spare parts” that is based on on-demand production

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 Obiettivo del progetto (Objective)

'The proposal offers a solution for the growing quantity of product types on the market requiring enormous warehouses to keep stock for spare parts, with corresponding high costs and complex logistics. This emerging problem is caused by the continuously decreasing product life time, decreasing time-to-market and increasing regulatory affairs. A solution is foreseen using Rapid Manufacturing (RM) technology, enabling economically viable, one-off manufacturing on demand. The full DirectSpare business model allows for manufacturers to rapidly produce only those spare parts that are required, at a location close to the equipment that needs to be repaired. This leads to the following advantages of DirectSpare and objectives of this project: • Aiming at this way of spare part supply, companies (especially SME’s) can keep or increase their competitive position. The step to introduce new products is made smaller because the compulsory spare parts supply becomes easier by the on-demand technology. This as alternative to stock supplied by high-volume production from low wage countries. • Huge cost reduction can be achieved on stock warehousing, such as warehouse building space, part depreciation costs, warehouse energy (light, heat), storage of tools, and the high start up costs for conventional part manufacturing. • Huge waste reduction as a large part of the stock will be destroyed in the end anyway because conventional volume manufacturing always exceeds the required quantity. • Huge environmental profit as conventional manufacturing of small quantities requires relatively high energy resources. • The decreasing product-life-cycle is not limited anymore by the corresponding warehouse characteristics. • Local service providers ensure local (EU) employment. • Before manufacture, a defect part will be improved to lengthen the spare parts’ life. The spare part can even be individualised for the specific user, usage and environment.'

Introduzione (Teaser)

Scientists developed a successful business model based on rapid, on-demand manufacture of individual spare parts. Exploitation should significantly reduce warehouse stock and associated costs.

Descrizione progetto (Article)

The number and variety of products available on the market are continuously increasing. At the same time, the lifetime of products is continuously decreasing as a result of rapid innovation and decreased time-to-market.

As a result, companies are required to keep warehouses full of spare parts for potential needs that may never arise. Such stock results in high costs, extensive scrap material and complex logistics management.

Rapid manufacturing (RM) technology, as its name implies, is a process that enable fast manufacture of often-complex parts. It has proved quite beneficial for production of prototypes and of small lots of novel products with particular importance for small and medium-sized enterprises (SMEs).

RM enables cost-effective manufacture of one-off parts on demand. Its obvious advantages as an alternative to warehouses full of (potentially useless) spare parts are the inspiration behind the EC-funded DirectSpare project. Scientists integrated computer-aided engineering (CAE) techniques with a unique set of design rules for a truly knowledge-based system (KBS).

Process automation was included where ever possible and new rapid design tools were developed. DirectSpare investigators developed standardisation of processes in manufacturing, logistics product and process certification and business management.

The system also required creation of the information and communications technology (ICT) required to catalogue all parts. In addition, scientists developed a total quality management (TQM) system and software tools for CAE and RM input data as well as for process control and final product quality.

All project objectives have been achieved and successfully demonstrated through application to selected case studies in several industries. In addition, a selection tool was developed to assess the suitability of a given part to RM processes and future research activities and business opportunities have been identified.

DirectSpare processes and tools should have important impact on reducing warehouse stock, capital depreciation, energy consumption related to warehouse management and materials waste as spare parts become obsolete. Resulting cost savings combined with rapid replacement of necessary parts will boost European competitiveness and be of particular benefit to SMEs.