Challenges Managing Duplicate Parts in Manufacturing


The level of complexity has greatly grown in manufactured products during the past ten years if you compare them to those from that time. Every maintenance department has duplicate parts or items in their item master, which is not a secret. While some businesses have done a fantastic job reducing duplication through restricted user input, stringent operating processes, and established data standards, others have found it difficult to handle the problem. 

Within a single production facility, we often observe 15-20% duplicate goods. But in multi-site businesses, the level of similarity might occasionally reach 25-30%. Duplicate products, which make up a significant amount of the MRO inventory value, pose a serious problem that stealthily increases inefficiencies and costs.


Also Read: “The Modern Guide to Overhead Manufacturing”

Duplicate Parts  Challenges

Cause of Duplication

Duplication is a problem that many businesses have, and it may be attributed to neither one product nor one person. Thousands of MRO spare parts are frequently kept on hand at each of the many manufacturing companies’ locations.  Which are dispersed across wide geographic areas. In such massive enterprises, numerous separate personnel enter data into several software systems at each location. Typically in different languages, with little to no common procedures. This lack of uniformity over time leads to inconsistent, erroneous, and incomplete material data, which leads to duplicate information.

Duplication’s Effects

Duplication can result in unneeded maintenance costs for businesses of hundreds, if not millions, of dollars. Replacements cannot be found, fake stock-outs happen, and repair staff rushes to expedite parts while there is a perfectly excellent part lying on the storeroom shelf. Equipment downtime and maintenance costs start to grow as the item master gets more and more clogged with duplicate information.

Parts Categorization and Elimination of Duplicate Parts

It’s difficult enough to manage hundreds or thousands of pieces. It might be really unsettling to consider categorizing them all. However, enterprises may get control over their components with the correct parts categorization solution. Manufacturers may save millions of dollars annually by minimizing duplicate components and maximizing reuse. Engineers may more readily locate the parts they need when they need them by categorizing parts and preserving them associatively throughout the product lifecycle. Cost savings, industrial efficiency, and supply chain agility are all made possible by a successful parts classification approach.


 Also Read: “5 Trending Manufacturing Technologies Impacting Product Development”

Using Product Lifecycle Management, Reduce the Number of Duplicate Parts

A product lifecycle management system, which serves as the cornerstone of the digital thread, offers the control and traceability required for efficient parts management. By adding more details to the component description, PLM enables manufacturers to categorize parts, making it simpler to separate parts by category. Hardware, electrically supplied components, and other components may fall under these categories.

Engineers don’t need to produce new components when they have access to information like this. Which makes it simple to discover existing parts that fit their design requirements. Both the technical team building the product and the teams who want the data, later on, can benefit from this knowledge. As a result, the supply chain can communicate more effectively about parts that are accessible.


Also Read: “Digital Transformation for Manufacturing – A Step in The Future”

Utilize KloudPLM to Address Issues with Part Duplication

The smooth part categorization capabilities of KloudPLM increase reusing. Configurable categorization schemes let you create a consistent naming and description structure for components in a way that makes the most sense for the company. As soon as it is configured, KloudPLM automatically gives components and documents names based on their classification. For the new components and paperwork. Their categorization is in accordance with corporate guidelines thanks to KloudPLM.

Additionally, KloudPLM offers localized text and measurements for extremely specialized search functionalities across several business areas after parts and documents have been categorized. Futhermore, you may utilize the program to provide components qualities that are relevant to sustainability requirements. Additionally, manufacturers may utilize KloudPLM to conduct bulk updates while retaining quality & accuracy in cases when a significant volume of data needs to be changed.

You can eliminate parts duplication, improve part categorization, and achieve significant cost savings and enterprise-wide efficiency using KloudPLM. Set up a demo with KloudPLM right now.

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