Cost Reduction Techniques For Maintenance Personals

26-27 Aug, 2024, Wyndham Grand Bangsar Kuala Lumpur

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Mr. P. Balachandran is a training consultant with over 18 years of experience in manufacturing and 23 years in training. Mr.Balachandran began his career in the Equipment Maintenance function in Motorola Malaysia and grew steadily to become an Equipment Engineer. He later took on a position as Section Head for a Production Unit which he ran for several years. He moved on to Tho Audio Electronics in Muar as a Production Manager in 1991 where he spent 2 years. Subsequently, he assumed a position as Production Manager and then as a Training and Education Manager at Samsung Electron Devices, Seremban till 1995 and then became a full time trainer in july 1995.

 

Mr. Balachandran specializes in Equipment Maintenance, Manufacturing and Training. since becoming a manufacturing trainer, he has conducted more than 700 training sessions covering more than 14,000 participants both in-house and public programs in last 23 years. He currently is one of the most prominent maintenance consultant for theoretical and subject matter expertise. He also specializes on TPM and have conducted numerous in-house training for the above topic. He is one of the most prominent trainer and consultant for RCM training and consultation.

 

His vast experience both hands-on and conceptual training makes him a valuable resource person for Maintenance Development in the Manufacturing and Service Sector. He was also invited to speak in Universities and in Maintenance Seminars and also trains hospital maintenance staff.

Venue Details

Wyndham Grand Bangsar Kuala Lumpur
No 1, Jalan Pantai Jaya, Tower 3, 59200 Kuala Lumpur, - 59200
Phone : (603) 2298 1888
Fax : (603) 2298 1999

https://all.accor.com/hotel/ 7962/index.en.shtml

Contact us

Juliany,
03 2283 6109
juliany@ipa.com.my

Phoebe,
03 2283 6100
phoebe@ipa.com.my 

FOR CUSTOMISED IN-HOUSE TRAINING
Jane,
03 2283 6101
Jane@ipa.com.my

ADDRESS 
A-28-5, 28th Floor, Menara UOA Bangsar, 
No.5, Jalan Bangsar Utama 1, 
59000 Kuala Lumpur
www.ipa.com.my

FOCUSING ON
  • Module 1: Introduction to Maintenance Cost
  • Module 2: Cost Reduction Technique 1 :
    “Eliminate Frequent = Equipment Breakdown”
  • Module 3: Cost Reduction Technique 2:
    “Enhance Component Reliability”
  • Module 4: Cost Reduction Technique 3:
    “Eliminate Over Stocking Of Spares”
  • Module 5: Cost Reduction Technique 4:
    “Eliminate Excess Maintenance Manpower”
  • Module 6: Cost Reduction Technique 5:
    “Eliminate High Utility Cost”
  • Module 7: Cost Reduction Techniques 6:
    “Invent and Implement Innovation”
  • Module 8: Cost Reduction Technique 7:
    “Make Cost Reduction As A Way Of Life”
OBJECTIVE

Co$t 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 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 course, covers and discuss the key elements in maintenance waste and areas that need
attention and how they should function to save overall maintenance cost.

AFTER ATTENDING THIS COURSE YOU WILL RETURN TO YOUR JOB…
  1. Identifying maintenance co$t structure.
  2. Knowing how to reduce overall breakdown co$ts.
  3. Improving part life span.
  4. Being able to reduce utilities co$t.
  5. Improving on manpower co$t reduction techniques.
  6. Knowing how to control on spare parts co$t reduction techniques.
  7. Inventing and implementing new ideas.
  8. Practicing co$t reduction as a way to life. (walk the talk)
WHO SHOULD ATTEND
  • Maintenance Managers
  • Maintenance Engineers
  • Maintenance Supervisors
  • All levels of Maintenance Personals
  • All PM Technicians
  • Equipment Improvement Technicians
METHODOLOGY
  • Interactive Lectures
  • Explanations
  • Case Studies
  • Group Discussions
  • Q & A Sessions
DAY 1
9:00

Module 1: Introduction to Maintenance Cost

  • Effective maintenance as 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
10.45

Module 2: Cost Reduction Technique 1 : “Eliminate Frequent = Equipment Breakdown”

  • Breakdown is the evil to cost escalation
  • Why equipments keep failing
  • 3 cultures maintenance
  • Strategies for zero breakdown
  • Proactive step 1: Implement autonomous maintenance
  • Proactive step 2: Implement schedule planned maintenance
  • Proactive step 3: Start predictive maintenance
  • Proactive step 4: Implement poka yoke
  • Proactive step 5: Implement discard maintenance
  • Proactive step 6: Implement maintenance prevention
  • Proactive step 7: Implement kaizen
1:00 Lunch
2:00

Module 3: Cost Reduction Technique 2:
“Enhance Component Reliability”

  • Good vs bad maintenance
  • Why parts fail prematurely
  • Reasons for mechanical failures
  • Reasons for electrical & electronic failures
  • Reasons for pneumatic & hydraulic failures
  • How to improve parts life span
3:45

Module 4: Cost Reduction Technique 3:
“Eliminate Over Stocking Of Spares”

  • Spare parts are expenses
  • Spares are silent profit killers
  • Proper spare parts management system
  • Saw -tooth wave for spart parts management
  • 4 golden rules for spare parts
5:00 End Day 1
DAY 2
9:00

Module 5: Cost Reduction Technique 4:
“Eliminate Excess Maintenance Manpower”

  • Maintenance is NVA
  • Cost associated with maintenance
  • Ideas for reducing maintenance manpower cost
  • ‘Recession mode every day’
10.45

Module 6: Cost Reduction Technique 5:
“Eliminate High Utility Cost”

  • What are utility cost
  • Why reduce utility cost
  • Electricity wastages
  • Water wastages
  • Air-cond wastages
1:00 Lunch
2:00

Module 7: Cost Reduction Techniques 6:
“Invent and Implement Innovation”

  • Three engineer mentality
  • Why innovate?
  • Initiative 1: Reduce electricity wastages
  • Initiative 2: Implement water conservation ideas
  • Initiative 3: Implement and reduce
    air-cond wastages
  • Initiative 4: Create multi-skill workforce
  • Initiative 5: Analyze maintenance cost and improve
  • Initiative 6: Monthly cost reduction themes
  • Initiative 7: Reward & recognize creative ideas
3:45

Module 8: Cost Reduction Technique 7:
“Make Cost Reduction As A Way Of Life”

  • Must do 1: Walk the talk
  • Must do 2: Avoid tai-chi mentality
  • Must do 3: Set-up cost reduction goals
  • Must do 4: Establish maintenance KPI
  • Must do 5: Eliminate 3 ‘mu’
  • Must do 6: Evaluate your strategies
  • Tangible cost reduction ideas
  • In-tangible cost reduction ideas
5:00 End of Course