Keeping a spare of every part is both expensive and unnecessary. The goal is to identify the parts that would stop the machine for a long time if they failed and keep spares only for those.
Prioritisation: three questions
- Does the machine stop if it fails?
- If yes, a critical candidate
- What is the lead time?
- Priority rises if it is long or the product is discontinued
- How many machines share it?
- One spare of a shared part protects many machines
Parts that often turn out critical
- PLC CPUs and power supply modules
- Communication modules and gateways
- Drives and servo drives running the main motion
- Operator panels (HMI)
- Safety relays
- 24 V DC power supplies
How should spares be stored?
- Store them in antistatic packaging in a dry place with stable temperature.
- Check that the spare's order number and firmware version match the one in the field.
- For devices with electrolytic capacitors stored unpowered for long periods, check the manufacturer's storage recommendations.
- Keep program and parameter backups next to the spare part where they are easy to find.
Repairing a failed board and putting it on the shelf is a practical way to grow your spare stock at low cost.
ELKAR supplies automation spare parts from stock or by sourcing, and repairs faulty modules to return them to your spare stock.
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