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BILL OF MATERIALS: Ensuring access to spare parts for mission-critical California steel mill

Solving a Baghouse Issue Without Going to the Poorhouse

A “baghouse” is where dust, fumes and other particulates from plant floor environments are pulled, collected and removed to ensure ultra-compliant air quality. Every mill knows, when the baghouse goes down, the entire plant shuts down. This client experienced breakdowns where the plant closed for up to a week, waiting for parts. They had no spare parts, and no data to upload into SAP – in fact, the only data available was in Italian, which was of no use. And while the project engineering firm from Italy supplied some recommended spare parts lists in Italian, they were incomplete.

Lack of Engineering Resources Added to the Challenge

This client had recently downsized their engineering workforce, so didn’t have the resources to perform capital projects. The decision was made to outsource baghouse design – which did not include Bill of Materials – and spares and critical spares were never set up.

It All Started With a Site Visit

SDI performed a field survey and walked the site, whereby we located and tagged every item. After essential OEM research, we created the BOM, imported info into XLS templates for bulk upload into SAP, and used these templates to ensure data portability – all while complying with the client’s master data taxonomy.

The Italian Connection

SDI scrubbed the client data and created new material numbers, part numbers and specs, as well as new Bills of Materials – all of which was given to the client to upload into their systems. Many parts typically ordered from Italy could now be ordered through local distributors or vendors – often more affordably, and with shorter lead-times. As a result: standard temperature sensors, flow sensors, environmental controls and over 100 yards of equipment could now be identified and mapped – without the Italian connection.

Immediate client benefits included:

  • Increased uptime
  • Production loss avoidance
  • Ease of operation
  • Greater control over the equipment
  • Holistic view of exactly what’s needed to maintain mission-critical equipment

A Successful and Repeatable Solution

The same process and approach taken for this client – and the same results – can be accomplished for any type of capital asset across virtually any industry vertical. Several user groups can benefit greatly – from Engineering managers and Maintenance planners & schedulers to Reliability managers.

The SDI Advantage

SDI understands MRO, so we understand the parts required for uptime and productive success. Leveraging our proven operating process and powerful ZEUS platform, we’re able to quickly create solutions that engineering firms and distributors simply aren’t structured to deliver.

We can identify the part, know where to source it, and understand the critical attributes that each vendor needs – so we get the right part, the first time. We give you the data to upload into SAP, so you can select the BOM that tells you everything you need in order to rebuild your equipment. Kitting is based on the BOM – so when the equipment needs to be worked on, we can create the kit so you have it BEFORE a shutdown, so you’re ready – no matter what.

Need BOMs for Warranty and Repair Tracking?

These can be independent, but effectively complement each other. Repairs are sustainable savings – let’s say you have a BOM structure, yet may not know what’s repairable. Best-case scenario: SDI manages the storeroom operations, so we have instant access to repairable parts – and complete tracking – while on-site.

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