COURSE OVERVIEW:

Spares interchangeability and Bill of Materials (BOM) control are essential functions for maintaining the technical integrity and cost-efficiency of rotating equipment fleets. In large-scale industrial plants, similar pumps, motors, and seals are often sourced from various vendors or installed across different process units. This course focuses on the systematic identification of identical components used in different applications, allowing organizations to reduce redundant inventory, leverage bulk purchasing power, and streamline maintenance planning.

The scope of this course covers the creation and management of a "Master BOM" and the technical verification required to confirm that a part intended for one machine can safely and effectively be used in another. Participants will learn how to navigate the complexities of "Part Number Proliferation" and use Spare Parts Interchangeability Records (SPIR) to map relationships between assemblies. The Coverage includes the critical role of technical documentation, such as cross-sectional drawings and material specifications, in ensuring that interchangeability does not compromise equipment performance or safety.

Furthermore, the training addresses the administrative controls necessary to keep BOMs accurate over the asset's lifecycle, including Management of Change (MOC) procedures for part substitutions. Attendees will explore how to audit their CMMS data to identify "hidden" duplicates and how to work with OEMs to verify technical equivalence. By the end of this program, participants will be able to implement a robust BOM control framework that serves as a reliable "single source of truth" for maintenance, procurement, and reliability teams.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Define the concepts of technical interchangeability and functional equivalence.
2. Develop and maintain accurate Bills of Materials (BOM) for rotating equipment.
3. Identify opportunities for inventory reduction through part standardization.
4. Utilize Spare Parts Interchangeability Records (SPIR) for fleet management.
5. Conduct technical audits of CMMS data to eliminate duplicate part entries.
6. Verify material and dimensional compatibility for part substitutions.
7. Implement a Management of Change (MOC) process for spare parts.
8. Distinguish between OEM, OPM, and alternative part sources.
9. Map "Where-Used" reports to assess the impact of part obsolescence.
10. Manage the relationship between physical assets and digital part catalogs.
11. Apply coding and classification standards (e.g., ISO 8000) to spares.
12. Collaborate with procurement to optimize bulk buying based on interchangeability.
13. Ensure that interchangeable parts meet original safety and design margins.
14. Perform periodic BOM reviews to reflect equipment modifications and upgrades.

TARGET AUDIENCE:

This course is intended for Maintenance Planners, Inventory Controllers, Reliability Engineers, CMMS Administrators, and Procurement Specialists.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.