About Maintenance Cost Reduction – Online Course

Learn how to radically reduce maintenance costs via advanced maintenance cost reduction techniques/solutions.

Course Outline

  • The course will start with systematic and structured analysis of the main maintenance types and the main maintenance costs
  • Cost-benefit analysis and life cycle cost techniques will be discussed in details
  • The methodology of maintenance type selection will be undertaken that play essential role in maintenance cost reduction
  • Optimal job frequencies of preventive/predictive maintenance will be determined that play an important roles in maintenance cost reduction
  • The advanced techniques: failure mode and effect analysis (FMEA) and failure mode, effect and criticality analysis (FMECA) for maintenance cost reduction will be discussed in details

Course Format

The course will be presented in an interactive format with ample details from the trainer. The trainer will use comprehensive Power Point slides, hand-outs and industrial case study material, including videos and practical exercises.

Who Should Attend?

This highly interactive training course will benefit anyone responsible for maintenance, who wishes to perform cost-effective plant maintenance. This includes:

  • Plant Directors
  • Senior Plant Managers
  • Maintenance Supervisors/Coordinators
  • Operation Managers and Supervisors
  • Materials and Storeroom Managers
  • Persons involved in plant maintenance
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  • Introduction
  • Maintenance: Definitions and the Main Concepts
  • Build Systematic
  • Maintenance Tactics for Your Plant
  • Maintenance Budget: Identifying the Main Maintenance Costs
  • Cost Benefit Analysis
  • Opportunity Maintenance for Essential Reduction of Plant Downtime and Maintenance Costs
  • Cost reduction via Operation Involvement in Routine Maintenance
  • The Main Maintenance Best Practice Planning Principles that Reduce Maintenance Costs
  • Wrench Time Reduction as the Main Leverage of Maintenance Cost Reduction
  • Life Cycle Cost Technique for Maintenance Cost Reduction via Optimal Asset Purchase and Disposal
  • Asset Functions: Primary and Secondary
  • Asset Failures: Potential and Functional
  • The Instantaneous Hazard (Failure) Rates
  • Cost Reduction by Optimal Selection of Job Frequencies for Predictive Maintenance Using the P-F Interval
  • Cost Reduction by Optimal Selection of Job Frequencies for Preventive Maintenance Using the MTBF
  • Optimal Selection of Job Frequencies for Predictive and Preventive Maintenance: Industrial Case Studies
  • Hidden and Evident Failures
  • Analysing Asset Failure Consequences for Maintenance Type Selection
  • Determining Asset Criticality is a Key Factor in Maintenance Cost Reduction
  • The Key Maintenance Metrics
  • Determining When to Prevent Failure and When to Allow Failure to Occur; Optimal Selection of:
      Predictive Maintenance
    1. Preventive Maintenance
    1. Failure Finding Maintenance
    1. Maintenance by Re-Design/Redundancy
    1. Breakdown Maintenance
  • <-Logic diagram for optimal maintenance type selection
  • The Comprehensive List of the Main Key Maintenance Performance Indicators that Determine Cost Effectiveness of Maintenance
  • Assessing Risks: Introduction
  • Risk Based Maintenance: Estimating Risks of Asset Failure and Prioritizing Maintenance Based on Risks of Asset Failures
  • Risk Based Maintenance: Industrial Case Study
  • Outsource Maintenance to Reduce Maintenance Costs
  • Maintenance Cost Reduction by Effective Spare Part Management
  • Failure Mode and Effect Analysis (FMEA) for Maintenance Cost Reduction
  • FMEA: Industrial Case Studies and Practical Group Exercises
  • Maintenance Cost Reduction by Effective Management of Maintenance Backlog
  • When Shutdown Should Start? Shutdown Stages:
      Pre-Shutdown Stage
    1. Shutdown Stage
    1. Post-Shutdown Stage
  • Effective Shutdown Preparation by Condition Monitoring, HAZOP and Event Tree Analysis for Avoiding Unknown Defects and Minimizing Shutdown Costs
  • Estimation of Shutdown Duration Using Cost-Benefit Analysis
  • Critical Path Analysis for Estimation of Shutdown Duration
  • Shutdown: External Risks
  • Determining True Shutdown Jobs
  • Key Performance Indicator for Plant Shutdown that Estimate Cost Effectiveness of Shutdowns
  • Root Cause Analysis of Fault/Failures for the Proactive Maintenance; an Approach of Six Root Factors
  • The Generic “Eight Disciplines Problem Solving” Technique for Root Cause
  • Analysis Planning for Work Orders
  • Fishbone (Ishikawa) Diagram for Root Cause Analysis
  • Root Causes of Assets Failures: Description
    Planning Industrial
  • Root Cause Analysis for Work Orders: Industrial Case Studies
  • Planning Failure Assessment for Work Orders: 9 Classical Steps
  • Planning Failure Assessment for Maintenance: Industrial Case Studies
  • Human Errors in the Proactive Maintenance
  • Maintenance Cost Reduction by Reduction of Human Errors
  • Review: Learning Outcomes
  • Closing Comments
Prof. Len Gelman
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Event Details
  • Start Date
    May 24, 2021 09:00
  • End Date
    May 26, 2021 17:00
  • Status
  • Location
  • Category


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