COURSE OVERVIEW:

Maintenance is often viewed as a "cost center," but when managed effectively, it becomes a "profit center" by maximizing asset availability and minimizing waste. This course focuses on the financial and strategic management of maintenance operations, providing participants with the tools to balance the technical needs of the plant with the economic realities of the business. It emphasizes the optimization of resources—labor, materials, and services—to achieve the highest possible return on the maintenance dollar.

The scope of this training involves the detailed study of maintenance budgeting, cost tracking, and value analysis. Participants will learn how to move beyond simple cost cutting to "Value Driven Maintenance," where every expenditure is justified by its impact on risk and production. The course delves into the financial implications of different maintenance strategies, comparing the long term costs of reactive, preventive, and predictive approaches.

Coverage includes the management of spare parts inventory costs, the economic evaluation of outsourcing vs. in-sourcing, and the use of Life Cycle Costing (LCC) for asset replacement decisions. Attendees will learn how to communicate the financial benefits of reliability to executive leadership, using metrics that resonate in the boardroom. By the end of this course, participants will be able to manage a maintenance department that is not only technically proficient but also financially lean and strategically aligned with the organization's profitability goals.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Develop a robust maintenance budget based on zero based or historical methods.
• Analyze the "Total Cost of Ownership" (TCO) for critical plant assets.
• Implement a "Value Driven Maintenance" framework to prioritize spending.
• Identify and eliminate the "Six Big Losses" in maintenance productivity.
• Calculate the Return on Investment (ROI) for reliability improvement projects.
• Optimize spare parts inventory levels to reduce carrying costs.
• Evaluate the "Cost of Unreliability" and its impact on the bottom line.
• Compare the economics of "Repair versus Replace" for aging equipment.
• Manage third party contractor costs through performance based agreements.
• Utilize CMMS data for accurate cost tracking and variance analysis.
• Present maintenance financial performance effectively to non technical managers.
• Implement "Lean Maintenance" principles to reduce waste and overhead.

TARGET AUDIENCE:

This course is designed for Maintenance Managers, Plant Managers, Asset Managers, Finance Business Partners for Operations, and Senior Reliability Engineers.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.