Cost Reduction Techniques for Maintenance Personals

27-28 Apr, 2017, Furama Hotel Kuala Lumpur

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Mr. P. Balachandran brings to this course more than 17 years of solid industrial experience in the manufacturing sector as well as 12 years in maintenance manufacturing training and consultancy.

 

His experience includes that of Equipment Engineer, Section Head of Production, Production Manager and Training & Education Manager with well known corporations such as Motorola, Thomson Audio Electronics and Samsung Electron Devices.

 

Mr. Bala then became involved in management consultancy and trained full time in specific areas of manufacturing and maintenance training. His natural leadership style coupled with his vast industrial experience makes a valuable partner and resource in developing the workforce of the manufacturing sector and in trouble shooting.

 

Mr. Bala has trained more than 3000 professionals and some of the companies that have benefited from his expertise include Komag Malaysia, Minolta, Silitek, Sony Malaysia, Robert Bosch, TDK Malaysia, Swedish Motor Assembly, Western Digital, Dell Computers, Texas Instruments, TNB, Genting Sanyen, PROTON, Teck See Plastics, Hicom, Philips Semiconductor, Airod, B Braun, Carsem, Dynacraft, Seagate Industries, Mattel, Perodua, Johnson & Johnson and Malaysian Airlines System.

Venue Details

Furama Hotel Kuala Lumpur
136, Jalan Changkat Thambi Dollah, 55100 Kuala Lumpur, - 55100
Phone : (603) 2788 8888
Fax : (603) 2788 8889

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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
  • Introduction to Maintenance Cost
  • Breakdown Cost Reduction
  • Utilities Cost Reduction
  • Manpower Cost Reduction
  • Spare Parts Cost Reduction
  • Invent and Implement Cost Reduction
  • Cost Reduction As A Way Of Life
OBJECTIVES

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. Learning how to reduce utilities co$t.
  4. Understanding the manpower co$t reduction techniques.
  5. Learning on spare parts co$t reduction techniques.
  6. Understanding on how to invent and implement new ideas.
  7. Making co$t reduction as a of way to life, walk the talk.
WHO SHOULD ATTEND?
  • All levels of Maintenance Personals
  • All PM Technicians
  • Equipment Improvement Technicians
  • Maintenance Supervisors
  • Maintenance Engineers
METHODOLOGY
  • Interactive Lectures
  • Explanations
  • Case Studies
  • Group Discussions
  • Q & A Sessions
DAY 1
9:00 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 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
1:00 Lunch

2:00

UTILITIES COST REDUCTION

  • The unattended energy loss
  • Unaccounted electricity loss
  • Unaccounted water loss
  • Inefficient management of air-condition
  • Ways to overcome utility losses
3:45 MANPOWER COST REDUCTION
  • Direct Vs in-direct labour
  • Maintenance overhead cost variables
  • Overtime cost Vs normal pay
  • Frequent replacement lossess
5:00 End of Day 1
DAY 2
9:00 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
10:45 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
1:00 Lunch

3:45 INVENT AND IMPLEMENT COST REDUCTION (cont.)
  • Do not wait until told
  • Avoid tai chi mentality
  • Set very changeling cost reduction goals
  • Invent and innovate
  • Work as team
  • Make kaizen your daily motto
5:00 End of Course