Course Overview
Cost Reduction Techniques For Maintenance Personals
Cost Reduction Techniques For Maintenance Personals plays very important role in every industry as the main life line for survival. When cost maintained at manageable low level, the profit margin increases. When cost not controlled, profit margin shrinks. Being one of the key element in customer requirement QCD, cost definitely plays very important role in all business.
Cost Reduction must be controlled at all levels more so a must in maintenance. maintenance departments usually spend money on buying spare parts, tools, modifications, overtime and other minor day to day expenditures. if all this are not controlled or well spend, this can become a major concern for PQCDSM. As such maintenance personals must know and contribute to overall cost saving for the their organizations.
This program, covers and discuss the key elements in maintenance waste and areas that need attention and how they should function to save overall maintenance cost.
This Cost Reduction Techniques training provides practical methods for reducing maintenance costs, improving equipment reliability, and supporting continuous improvement initiatives across industrial operations.
Course Objectives of Autonomous Maintenance
- Identify maintenance cost structure.
- How to reduce overall breakdown costs.
- How to reduce utilities cost.
- Manpower cost reduction techniques.
- Spare parts cost reduction techniques.
- How to invent and implement new ideas.
- Making cost reduction as a way to life. (walk the talk)
Who Should Attend
- All levels of maintenance personals.
- All PM technicians.
- Equipment improvement technicians.
- Maintenance supervisors.
- Maintenance engineers.
This course is suitable for professionals who want to strengthen their knowledge of Cost Reduction Techniques in maintenance management.
Duration: 2 Days (9am to 5pm)
Course Content
Module 1: Introduction to maintenance cost.
- Effective maintenance as a tool to achieve PQCDSM.
- Equipment cost contribution to operation.
- Elements of life cycle cost to operation.
- Why cost control becomes important.
- Maintenance personnel role in cost reduction.
- General cost distribution in maintenance.
Module 2: Breakdown cost reduction.
- Why equipments keep failing.
- 3 cultures maintenance.
- PQCDSM losses due to breakdown maintenance.
- Run to fail strategy.
- Lack of proactive maintenance.
- Failure of inspection and monitoring.
- Absence of predictive maintenance.
- Lack of poka yoke techniques.
Module 3: Utilities cost reduction.
- The unattended energy loss.
- Unaccounted electricity loss.
- Unaccounted water loss.
- Inefficient management of air-condition
- Ways to overcome utility losses.
Module 4: Manpower cost reduction.
- Direct vs in-direct labour.
- Maintenance overhead cost variables.
- Overtime cost vs normal pay.
- Frequent replacement losses.
Module 5: Spare parts cost reduction.
- Where does the money for spare part came from.
- Why parts frequently fail.
- Understanding spare part criticality.
- Manage your spare parts prudently.
Module 6: Invent and implement cost reduction.
- Working on introducing high efficient light source.
- Working on reducing power factor loss.
- Work on improving auto power off.
- Work on reducing water wastage.
- Implement water conservation initiatives.
- Implement and control air-condition system.
- Develop strategies for zero breakdown.
- Implement poka yoke for fail safe misuse.
Module 7: Cost reduction as a way of life.
- Do not wait until told.
- Avoid tai chi mentality.
- Set very changeling cost reduction goals.
- Invent and innovate.
- Work as teams.
- Make kaizen your daily motto.
Participants will be able to implement Cost Reduction Techniques using practical maintenance strategies, continuous improvement practices, and effective cost management methods.
