Many companies must tighten the belt: costs must be reduced. Purchasing reacts by comparing prices when procuring spare parts and tries to keep stocks low. The offers for compatible spare parts or components are tempting: convenient online ordering, short delivery times, up to two thirds cheaper. Voilà. Mission accomplished.
Production line managers pursue a different strategy. For them, high system availability and low reject production are on the winner's podium in the race for cost savings. But can reliable adhesive application be achieved without unplanned downtimes if third-party spare parts are used?
Third-party spare parts are components that are compatible with original products, in our case from Robatech. However, if a replica part is offered as an original Robatech part, it is considered to be a counterfeit part. In this scenario, a third-party supplier is already acting illegally.
What third-party and counterfeit spare parts have in common is the lack of adherence to key technical standards and quality controls which Robatech guarantees. Consequently, compatible spare parts become a dangerous generic product. Although they are cheaper to buy than the original, they are not sufficiently tested for safety and functionality. After all, the parts used in an application system for hot melt adhesives have to withstand temperatures of up to 200 °C and high pressures.
Wear parts that fulfill a critical function in hot melt application are considered sensitive. They have a decisive influence on the productivity of the line and the quality of the adhesive application. It is therefore essential to use genuine solenoid valves, jetting elements and application nozzles, as well as filters in the melter and application head. This is the only way to guarantee that the adhesive application system operates reliably and safely.
Nevertheless, the temptation is great. For example, a replica SX-Diamond jetting element costs a third of the original price. But with a service life of 10,000 operating cycles, it is only built for one sprint, while the original Robatech part, with 250 million operating cycles, from Robatech easily completes the marathon. After every sprint, the machine comes to a standstill—driving up costs.
Depending on the situation, an unplanned downtime can generate costs of between 1,000 and 12,000 euros per hour. Exact figures can be calculated depending on the risk of downtime. The downtime costs depend heavily on the type of product and the duration of the standstill.
Apart from the generally shorter service life of compatible spare parts, their susceptibility to malfunctions can also cause costs. A typical issue with counterfeit jetting elements: Hot melt leaks uncontrollably and flows into the machine because the application nozzle no longer closes properly. As a result, in addition to downtime costs, there are also costs for cleaning or repairs on the production line.
This question is certainly provocative, but it is meant to be constructive. It is intended to encourage a holistic view of the costs of spare parts.
Stakeholders in purchasing, operations management, supply chain management and the Executive Board and Group Management should be aware of the technical risks involved in purchasing third-party spare parts. This is the only way to ensure that cost-cutting measures are not torpedoed by unforeseen high downtime costs.
Our experience from service assignments with customers confirms that quality and preventive measures can permanently reduce operating costs in the long term.