Maintenance Cost Control introduces delegates to concepts and techniques that can help to lift the maintenance performance and the contribution of maintenance to business performance to a higher level.In particular, this training course introduces delegates to techniques to drive improvements to maintenance performance through more disciplined approaches to management and workflow control processes, reliability improvement and optimization of preventive maintenance, the use of effective performance measures and decision making, and the implementation of effective logistics support for maintenance.

By the end of this training course, participants should be able to:

• Apply proactive management practices to improve the effectiveness of their maintenance management system
• Apply reliability and risk based approaches to optimize preventive maintenance and improve reliability
• Develop and implement a balanced asset management strategies
• Develop and implement an enhanced performance measurement scorecard and link this to more effective decision making in maintenance
• Optimise the maintenance logistics support functions
• Design maintenance audit programs that align to the highest priorities of their organizations
• Understand the principles of maintenance best practice
• Appreciate a range of auditing processes from benchmarking to achieving external accreditation such as PAS 55 and ISO 55000
• Build an in-house audit capability to cover the majority of functions and know when and how to engage external specialists effectively
• Use auditing to launch performance improvement programs and then help them succeed

This course is suitable for maintenance managers and supervisors, planners, schedulers, reliability engineers, project managers, project engineers, operations managers, shift managers, operations supervisors and professionals who are in training for these roles.  

During this Cost-Effective Maintenance Management training course, participants will learn through their active participation, review of relevant case studies, reference to programme workbook, participation in individual and group exercises, undertaking of various maintenance strategies and policies, exploration of maintenance tools and models, review of various training videos and practical peer group discussions of “real life” issues within their respective organisations. 

The course uses a mix of interactive and hands-on techniques. Beside the brief presentations by the facilitator and the participants, there will be many individual and group exercises based on actual maintenance audit-related scenarios. 

Introduction to Cost Effective Maintenance Management

• Introduction to Cost Effective Maintenance Management
• Key Maintenance Definitions
• The Management Process in Maintenance
• Maintenance and Competitive Advantage
• Cost minimization through Lean thinking
• Overall Equipment Effectiveness
• Total Productive Maintenance
• Exercises

Concept of Best and Worst Practice in Estimating the True ‘Value’ of Maintenance

• Why Systems Fail?
• Cases of Failures From Different Industries
• Failure Analysis and Technical Causes of Failures
• Generic Lessons Learned and Improvements
• Applications in oil and gas industries

Key Performance Indicators and Project Planning & Scheduling

• Measuring Maintenance Performance
• Key Performance Indicators for Maintenance
• The Balance Score Card.
• Developing the Maintenance Scorecard
• Planning tasks and their costs
• Importance of Planning and Scheduling
• Project Management Techniques for Optimisation
• Network Analysis
• Critical Path Analysis
• Optimisation of PM Schedules
• Optimum Resource Allocation
• Resource leveling
• Resource smoothing
• Maintenance Cost control, Budget and estimation
• Resource Planning
• Case Studies and hands-on exercises

Reliability Tools for Maintenance Cost Control

• Introduction to Reliability Concepts
• A Reliability Based Approach to Maintenance Strategy
• Failure Modes and Effects Analysis
• Risk Concepts and Risk Based Maintenance
• Preventive Maintenance Optimisation
• The Maintenance Value Chain
• The maintenance balanced score card (an alternative to Activity based costing)
• Exercises

Optimum Reliability and Maintenance Strategy - Policy Selection and Decision Analysis 

• How to get the most of your Computerized Maintenance Management Systems (CMMS)?
• Benefits that can result from CMMS
• How to transform Data to Decisions
• Examples of Approaches and Case Studies
• Case Studies and exercises from industry

A RECTUS attendance certificate will be awarded to all participants who complete at least 80% of the total course duration.