Cost Effective Maintenance

Why Attend

Maintenance can be an expensive function, but badly planned and poorly performed maintenance can incur significantly greater costs to an organization. Recent years have seen an increasing pressure to “reduce the cost of maintenance”, but this pressure frequently generates a push toward fixed cost reductions without sufficient consideration of the consequences on plant performance, production costs, asset life and even HSE. Some initiatives achieve short-term fixed cost reductions, but cause longer-term issues, such as poor reliability, that have a far greater adverse impact on bottom-line profits.

Overview

Course Outline

Schedule & Fees

Course Methodology

This is an interactive course. There will be open discussions, regular team exercises, videos, case studies and presentations on best practice and models. Participants will have the opportunity to discuss maintenance approaches from their own organizations and to develop maintenance plans with the facilitator and other participants on the course.

Course Objectives

By the end of the course, participants will be able to:

Understand the definition and principles of cost effective maintenance
Calculate the total cost of maintenance for their own production plant
Build a strategy and business case to eliminate waste and develop lower maintenance costs without losing reliability
Use the model of excellence for optimizing fixed costs of maintenance
Explain the fundamentals of cost effective safety and legislative compliance
Help focus reliability efforts in a cost effective way
Develop an approach to integrate cost reduction with reliability and safety improvement

Target Audience

Maintenance managers and supervisors, planners, schedulers, reliability engineers, project managers, project engineers, operations managers, shift managers, operations supervisors and/or individuals who are in training for these positions. This course is also designed for contractors who want to contribute to maintenance and shutdown performance of clients.

Target Competencies

Analyzing maintenance costs
Developing efficiency improvements
Identifying essential maintenance and quality requirements
Cost optimization
Maintenance planning
Reliability improvement

Understanding the total cost of maintenance

A definition of the total cost of maintenance
Benchmark standards
Where to find best practice
Key components of fixed costs
Cost of lost production
Cost of non -compliance
How maintenance can add value to a business
How to establish a balanced approach to defining cost effective maintenance
Who influences maintenance cost effectiveness?
Changing spending behaviors

The modern maintenance strategy

How maintenance has evolved
Understanding where money should be invested and where money tends to be wasted
The importance of planning
The relationship between fixed costs and maintenance performance
A change in thinking

Away from cost reduction or reliability or safety
Towards cost reduction and reliability and safety

The modern maintenance strategy and asset management
How pace setters have added value through maintenance innovation and integration with operating teams

The basics of fixed cost reduction

Understanding the basic categories of spend
How to map maintenance costs
Getting to the root cause of spend
The danger of managing by averages
Setting out a maintenance cost reduction program
Setting KPIs and sustaining change

Focus areas for fixed cost reduction

Eliminating waste

Understanding the different types of maintenance
Common causes of waste
The importance of planning
The principles of risk based maintenance
The importance of maintenance standards

Efficiency improvements through smart ways of working

Identifying efficiency opportunities
Tool time improvement
Improving maintenance methods
Learning from other sectors
Implementing a planned maintenance regime

Reducing supply chain costs

Contractor strategies
Spare parts and materials
Equipment and bought in services

Plant performance and reliability improvement

A model of excellence for reliability improvement
The reliability roadmap
How to make sure reliability improvement is efficient as well as effective
Understanding the different types of maintenance
Overall equipment effectiveness and other performance measures
Improving asset life
Learning from experience
The role of operations
How to use different maintenance types to improve performance
How to achieve the same performance at lower costs

Cost effective Health Safety & Environment (HSE)

The value of HSE improvement
How poor performers add unnecessary costs through safety
Integrating HSE within the wider maintenance strategy
Managing legislation
The principle of risk based inspection
Reducing the cost of compliance

The importance of shutdown management

Origins of the model of excellence and why it was developed
A graphic model - The critical elements required for success
An outline model - Exploring the sub elements
A detailed model - The blueprint for success
The importance of strategy and the principle of front end loading
How pace setters have moved to structured work processes

Processes for safety and quality control
Defining the right shutdown organization
Planning and logistics
Execution and review

Shutdown economics from forecasting to closure

Accra

Accra (Ghana)2025-09-22$2100

Arusha

Arusha (Tanzania)2026-05-25$1995