MAINTENANCE COST REDUCTION THE RIGHT WAY WITHOUT UNDESIRABLE IMPACT ON PRODUCT QUALITY

Share:

INTRODUCTION TO MAINTENANCE COST REDUCTION THE RIGHT WAY WITHOUT UNDESIRABLE IMPACT ON PRODUCT QUALITY

Many of us have had bad experience of cost initiatives that have failed to deliver lasting gains. Why is this such a difficult challenge? The underlying challenges in maintenance cost reduction without undesirable impact on product quality include resistance from the organisation, to cut a little from each division as a acceptable way to share the pain, rather than looking at where resources could be best deployed or the underlying reasons why costs in some areas are needlessly high.

Start with strategy, have a clear view of your strategy and ensure it is consistently understood across the organisation, align costs to strategy, differentiate the strategically-critical good costs from the non-essential bad costs, set direction and show leadership, deliver cost optimisation as a strategic, maintenance transformation programme, create a culture of cost optimisation, ensure you embed a culture of ownership and continuous improvement.

 

KEY OBJECTIVES

  • Understand how to prevent breakdowns.
  • Reduce maintenance costs is to prevent malfunctions
  • Track and manage inventory
  • Analysing maintenance costs
  • Maintenance planning
  • Reliability improvement
  • Developing efficiency improvements
  • Cost optimization
  • Choose the right maintenance strategies
  • Understanding component warranty/insurance period.
  • Extend component useful life, identifying right maintenance strategies
  • Develop your team to have the cost optimization culture mindset

 

THIS COURSE IS RECOMMENDED FOR

  • Middle Managers
  • Maintenance Managers
  • Maintenance Supervisors
  • Maintenance Engineers
  • Line leaders
  • Production supervisors
  • Maintenance Technicians

 

COURSE CONTENT

Module 1
Introduction – Strategy the cost management process

  • A definition of the total cost of maintenance
  • Capital and revenue costs
  • The importance of cost awareness
  • The importance of cost reduction
  • Benchmark standards cost-benefit analysis
  • Where to find best practice
  • Key components of fixed costs
  • Key components of variable costs

 

Module 2
Overheads and Breakdown Costs

  • Activity-based costing (ABC) – the principles
  • Where and how the ABC approach may be helpful
  • Know the ‘true’ cost of a machine breakdown loss
  • How to map maintenance costs
  • Getting to the root cause of spending
  • Risk mitigation Overall Equipment Effectiveness
  • Equipment Availability
  • Performance
  • Quality

 

Module 3
Implement a Successful Optimal Maintenance Strategy

  • How to use different maintenance types to improve performance
  • Preventive maintenance
  • Predictive maintenance
  • Pick the Optimal Time to Perform Maintenance
  • Extend Time Between PMs
  • Identifying efficiency opportunities
  • Tool time improvement
  • Improving maintenance methods
  • Take Corrective Action for Chronic Failures
  • Efficiently scheduling maintenance work

 

Module 4
Manage continuous improvements

  • Reliability program
  • Overall equipment effectiveness and other performance measures
  • Forecasting component failures
  • Improving asset life
  • Learning from experience
  • The role of operations
  • How to achieve the same performance

 

Module 5
Leverage upon Vendor Partnerships Purchasing

  • Supplier partnership
  • Supplier relationship
  • Qualifying suppliers
  • Reducing supply chain costs
  • Contractor strategies
  • Planning and Scheduling Strategy
  • Manage warehouse Inventory
  • Spare parts and materials

 

Module 6
Set Up a Repair Program Cost Avoidance

  • Prioritizing Maintenance and Repair
  • Internal And External Repairs
  • Standardization of Parts and Services
  • Cost of lost production
  • The risks of poor cost control
  • Benchmarking Maintenance Costs

 

Module 7
Create a Culture of cost optimization

  • Start with strategy, a clear view of your strategy
  • Roles and Responsibilities
  • Team Composition
  • Task Sharing meeting objectives
  • Differentiate the critical good costs from the non-essential bad costs
  • Create a culture of cost optimization:
  • Create S.M.A.R.T. goals
  • Applying CMMS
  • Tracking maintenance Cost Indices

 

HOW TO SEND US AN ENQUIRY?

  1. Fill in the form below and submit it to us. A popup message “Thank you for your message, our sales person will contact you soon.” will appear after a few seconds.
  2. Initiate a conversation via live chat on the bottom left of our website by stating: ‘Hi, my name is [your-name]. I’ve already submitted the form for this training.’
  3. We’ll promptly reach out to you regarding the training you’re interested in.
MAINTENANCE COST REDUCTION THE RIGHT WAY WITHOUT UNDESIRABLE IMPACT ON PRODUCT QUALITY

ENQUIRY form

    ORGANIZATION DETAILS






    PERSON-IN-CHARGE DETAILS




    FOR FURTHER INFORMATION, PLEASE CONTACT US!