Analyzing the Use of Spare Parts

Oct 13, 2025 by vinooalluri.com 60 views

Optimizing the Cost of Machine Spare Parts in PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi

Introduction

In today's competitive business landscape, companies are constantly seeking ways to optimize their operations and reduce costs. One area that often gets overlooked is the management of machine spare parts. Effective inventory management is crucial for ensuring the smooth operation of machines and equipment, while also minimizing costs. In this article, we will explore the importance of controlling inventory of factory machine parts at PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi, a company engaged in the processing of palm oil.

The Challenge of Spare Parts Inventory Management

PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi, like many other companies, faces the challenge of managing its spare parts inventory. The company has machines and equipment that require spare parts to ensure operational smoothness. However, spare parts in the warehouse incur storage costs, and the longer they are stored, the greater the investment costs. On the other hand, spare parts storage that is too short will increase the frequency of purchases and booking costs. Therefore, companies need to control effective and efficient spare parts inventory to minimize total costs.

The Current State of Spare Parts Inventory Management at PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi

Although the company's policies have been able to maintain the smooth availability of spare parts, non-fixed order systems and ordering quantities that are too large result in inventory costs that are not optimal. To overcome this, this study aims to find solutions to get a more economical total inventory cost by utilizing the Economic Order Quantity (EOQ) method and the lot for lot (LFL) method.

Methodology

This research was conducted by analyzing 40 engine parts items, with the following steps:

Analyzing the Use of Spare Parts

Data on the use of spare parts based on the "break down time" machine is analyzed to understand the pattern of use and needs.

Critical Spare Parts Identification

ABC classification is used to identify 12 critical parts items that have a significant impact on factory operations, including:

Phericall Roller Bearing
Roller Clain Pitch
Left & Right Handed Worm P/N 13
Nozzle
Press Cylinder to 12
Bcarer Ref 7 AC.Ar.al
Coupling P/N 58949044
Trust Miracle
Steam Pipe
SKF Bearing 29326
Top Screen Assembly Mesh 40
Top Screen Assembly Mesh 30

Determination of the Amount of Economic Order

EOQ method is used to calculate the optimal order, minimizing the cost of ordering and storage.

Re-Ordering Point

Reorder point (reorder point) is calculated to ensure the availability of spare parts before the inventory runs out.

Results

The results showed that the application of the LFL method was able to reduce total inventory costs from Rp. 17,528,250 to Rp. 6,630,000, or savings of Rp 10,898,250 (49.93%).

Benefits of Research

Cost Savings

The application of the LFL method allows companies to save inventory costs significantly.

Increasing Efficiency

This method helps companies optimize parts inventory management, increase operational efficiency.

Prevention of Inventory Deficiency

By setting the right re-ordering point, the company can prevent the deficiency of spare parts and production disorders.

Conclusion

This study provides an effective solution to optimize the cost of spare parts inventory at PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi. The application of the LFL method can be a strategic step for companies to improve efficiency and profitability. By implementing this method, companies can reduce costs, increase efficiency, and prevent inventory deficiency.
Frequently Asked Questions (FAQs) on Optimizing the Cost of Machine Spare Parts in PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi

Q: What is the main challenge faced by PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi in managing its spare parts inventory?

A: The main challenge faced by PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi is the non-optimal inventory costs due to non-fixed order systems and ordering quantities that are too large.

Q: What is the Economic Order Quantity (EOQ) method and how does it help in optimizing spare parts inventory?

A: The EOQ method is a mathematical formula used to determine the optimal order quantity that minimizes the total cost of ordering and holding inventory. By using the EOQ method, companies can determine the optimal order quantity that balances the costs of ordering and holding inventory.

Q: What is the lot for lot (LFL) method and how does it help in optimizing spare parts inventory?

A: The LFL method is a simple and effective method of inventory management that involves ordering a fixed quantity of inventory at regular intervals. By using the LFL method, companies can reduce inventory costs and improve operational efficiency.

Q: What are the benefits of implementing the LFL method in PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi?

A: The benefits of implementing the LFL method in PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi include:

Reduced inventory costs
Improved operational efficiency
Prevention of inventory deficiency
Increased profitability

Q: How can companies identify critical spare parts items that have a significant impact on factory operations?

A: Companies can identify critical spare parts items by using the ABC classification method, which categorizes spare parts into three categories: A (high-value, high-usage items), B (medium-value, medium-usage items), and C (low-value, low-usage items).

Q: What is the reorder point and how does it help in ensuring the availability of spare parts?

A: The reorder point is the point at which a company needs to reorder spare parts to ensure that they are available when needed. By setting the right reorder point, companies can prevent inventory deficiency and ensure that spare parts are available when needed.

Q: How can companies implement the LFL method in their spare parts inventory management?

A: Companies can implement the LFL method by:

Identifying critical spare parts items
Determining the optimal order quantity using the EOQ method
Setting the reorder point
Ordering a fixed quantity of inventory at regular intervals

Q: What are the future directions for optimizing the cost of machine spare parts in PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi?

A: The future directions for optimizing the cost of machine spare parts in PT. Perkebunan Nusantara III PKS Rambutan Tebing Tinggi include:

Implementing a just-in-time (JIT) inventory system
Using advanced inventory management software
Conducting regular inventory audits and analysis
Continuously monitoring and evaluating inventory performance.