On Demand Spare Manufacturing

Overview

On Demand Spare Manufacturing is the manufacturing of spare parts as-needed as opposed to a traditional stockpiling approach. It leverages digital manufacturing technologies such as additive manufacturing, 3D scanning, optimization algorithms, and supply chain logistics. On Demand Spare Manufacturing requires identifying the need for a spare, transporting materials for manufacturing, scanning, processing, mesh generating, manufacturing the spare part, finishing, inspecting, transporting the spare part to the system, and installing the replacement part.

Roadmap Model using Object-Process-Methodology (OPM)

The graphic below depicts the different processes by which a need for a spare part is identified. Depending on different factors, such as the industry and risk tolerance, the need for a spare may arise differently. For example, a spare may be needed to replace a component during routinely scheduled maintenance as opposed to a spare that is required because a component failed. In the first case, the need for the spare can be anticipated ahead of time; in the second case, the need arises unexpectedly.

The graphic below depicts the primary objects and processes associated with On Demand Spare Manufacturing. In this model, humans are only identified when they are active participants in the process. Humans are not identified as actors if they are passive participants, such as an operator running a machine.

Figures of Merit

Figures of Merit

FOM	Description	Unit	Trend
Turn-Around-Time	Time from need identified to need met	hr	decreasing
Cost	Total replacement part cost	$	decreasing
Feature Size	The smallest detail that can be reproduced	μm	constant
Lifespan	Replacement part lifespan	year	constant
Material Cost	Raw material cost	$/kg
Production Cost	Aggregate cost of labor, machine time, etc...	$/hr	decreasing
Material Waste	Excess material utilized in the production process	%	decreasing
Defect Rate	The fraction of parts produced that are not suitable for use	%	constant