Maintenance & Cost Reduction

13-14 Mar, 2023, Pullman Kuala Lumpur Bangsar

IPA Training is Registered with

Learn from the Best

Ir. Dr. JAYASEELAN has about 30 years of experience in various industries.


He was a recipient of the Association of Overseas Technical Scholarships (AOTS) award on two
occasions, awarded by the Ministry of Economy, Trade and Industry of Japan. Ir.N.Jayaseelan was also a member of the working group to draw up the energy efficiency and energy conservation guidelines for pumps and
compressors for Malaysian industries organised by the Institution of Engineers, Malaysia, Pusat Tenaga Malaysia, and the Ministry of Energy, Water and Communications (KTAK).


Professionally trained in mechanical engineering, he is positive and lively in his approach. He livens his audience by always providing interactive and energetic presentation of his material in a comprehensive and easy to use
format of ideas that work. His participants describe him as a very creative, fun and lively trainer who sets high standards.


He graduated from the University of Malaya, Leeds Polytechnic, UK and Universiti Putra
Malaysia and holds a Degree in Mechanical Engineering, Masters in Engineering and a doctoral degree in
His wide hands-on industrial experience has enabled him to design and facilitate training courses.


Some of the companies he has trained includes, Tenaga Nasional Bhd, Bank Pembangunan, Ranhill, Ebara Pumps, Usaha Tegas Sdn.Bhd (Maxis), Infineon (M) Sdn.Bhd, Universiti Malaya, Universiti Teknologi Malaysia, Penang Port Sdn.Bhd. Cement Industries of Malaysia Berhad, Politeknik Mukah (Sarawak), Petlin Malaysia Sdn Bhd,
Bintulu Port, Sime Austral, Perbadanan Putrajaya Holdings, Syarikat Air Johor, ORYX, Carsem, Unisem


• Fellow of the Institution of Engineers, Malaysia (FIEM)
• Professional Engineer, Board of Engineers, Malaysia (PEng)
• Member of the Association of Consulting Engineers, Malaysia (MACEM)
• Member of the Institution of Engineering & Technology (MIET), UK;
• APEC Engineer
• International Professional Engineer;
• Member of Engineers Australia / Chartered Professional Engineer, (MIEAust CPEng
• Registered Electrical Energy Manager with the Energy Commission of Malaysia

Venue Details

Pullman Kuala Lumpur Bangsar
No 1 Jalan Pantai Jaya, Tower 3, 59200 KUALA LUMPUR,
Phone : 0 3-2298 1888
Fax : 0 3-2298 1999 /index.en.shtml

Contact us

M - 012 2281 247

M - 019 363 7822 

M - 012 941 8251

A-28-5, 28th Floor, Menara UOA Bangsar, 
No.5, Jalan Bangsar Utama 1, 
59000 Kuala Lumpur

  • Introduction to Maintenance & Cost Reduction
  • Equipment Management & Cost Reduction
  • Preventive Maintenance & Cost Reduction
  • Maintenance Operations Analysis & Cost Reduction
  • Maintenance, Reliability & Cost Reduction
  • Commissioning, Troubleshooting & Cost Reduction
  • Total Productive Maintenance & Cost Reduction
  • Maintenance Execution & Shutdown:- Best Practices & Cost Reduction
  • Maintenance of Complex Equipment:- Issues, Challenges & Cost Reduction
  • Case Study:-Maintenance and Service of your Circuit Breaker & Cost Reduction
This course is designed to provide an understanding of engineering related problems related to industry globally and a clear sense of what is required to effectively structure, establish measurements and solve problems. Participants will learn the goals and deliverables behind the solutions. Methodology as well as the most commonly used tools within each phase will be discussed. Participants will also learn how to support a problem solving initiative within their organization.
  1. Understanding the benefits of professional maintenance planning, scheduling & control techniques and relate the concepts to the overall business mission and objectives.
  2. Thinking about his/her organization as a collection of processes, with inputs that determine the output.
  3. Using the maintenance planning, scheduling & control concept to evaluate the capability of a process or organization.
  4. Recognizing the maintenance planning scheduling & control model used to improve processes.
  5. Recognizing the organizational factors that are necessary groundwork for a successful
    engineering problem solving program.
  6. Being able to Integrate maintenance planning, scheduling & control efforts with other process
    improvement initiatives.
Engineers, technologists, technicians, QC/QA personnel, R&D personnel and any one involve in continuous improvement activities etc.
  • The latest educational methods and strategies will be utilized.
  • The course is designed to maximize delegate participation.
  • Questions and answers are encouraged throughout and at the daily wrap-up sessions.
    This gives participants the opportunity to discuss with others and the course leader their
    specific problems and appropriate solutions.
  • The course shall be conducted through lectures, case studies, group discussions and
    exercises to reinforce participant’s learning.

Introduction to Maintenance & Cost Reduction

  • Failure
  • Maintenance in the Service Industry
  • Maintenance in Manufacturing Companies
  • Principle Objectives in Maintenance
  • Problems in Maintenance
  • Maintenance Costs
  • Types of Maintenance



Equipment Management & Cost Reduction

  • Equipment Management Benefits
  • Selecting and Acquiring Equipment
  • Negotiating Equipment Acquisition
  • Equipment Installation
  • Equipment Calibration
  • Performance Evaluation
  • Function Checks



Preventive Maintenance & Cost Reduction

  • Definition of Preventive Maintenance (PM)
  • Reasons for the increased need of PM
  • Advantages of a PM system
  • When to use a PM system
  • The law of PM
  • Guide to a successful PM system
  • Execution process


1:00 Lunch

Maintenance Operations Analysis & Cost Reduction

  • Maintenance Operations Procedures
  • Regular Maintenance Tasks
  • Maintenance operating proceduresin an aluminium fabricating plant
  • Implementing Specific Maintenance Activities
  • Expectations of Maintenance personnel
  • Equipment Inspections
  • Work Requests
  • Work Orders



Maintenance, Reliability & Cost Reduction

  • Strategic Importance of Maintenance and Reliability
  • Important Techniques
  • Overall System Reliability
  • Failure Rate
  • Computerized Maintenance System
  • Maintenance Costs
  • Increasing Repair Capabilities
  • Establishing Maintenance Policie 


5:00 End of Day 1

Commissioning, Troubleshooting & Cost Reduction

  • Commissioning Checklists
  • General Start-Up Procedures
  • Detailed Walkthrough
  • Visual module inspections
  • The Maintenance Plan


Total Productive Maintenance & Cost Reduction

  • TPM as a Lean Initiative
  • Effective TPM Eliminates 5 Losses
  • Downtime Database
  • Minimum Downtime Tracking
  • Operator Maintenance Partnership
  • TPM Tag System
  • Quality and Productivity



Maintenance Execution & Shutdown:- Best Practices & Cost Reduction

  • Effective Maintenance for Safety
  • Maintenance Execution
  • Job Screening
  • Scoping
  • Planning
  • Scheduling
  • Execution
  • Close-Out
  • Shutdown Steering Group
  • Shutdown Criteria
  • Job List Review
  • Shutdown Communication
  • Post-Shutdown Review


1:00 Lunch

Maintenance of Complex Equipment:- Issues, Challenges & Cost Reduction

  • Out-Sourcing of Maintenance
  • Strategic Maintenance Management
  • Maintenance of Leased Equipment



Case Study:-Maintenance and Service of your Circuit Breaker & Cost Reduction

  • The Circuit Breaker:- An essential part of your power system network
  • Service criteria for circuit breakers
  • Maintenance status of your circuit breaker
  • Service criteria
    - Aging
    - Mechanical
    - Life time endurance / electrical
    - Annual maintenance
    - Extended warranty
  • Maintenance policy based on the O&M manual 


5:00 End of Course