COURSE OVERVIEW:

The availability of the right spare part at the right time is often the difference between a minor disruption and a catastrophic outage. This course provides a strategic framework for managing "Critical Spares" and the growing challenge of "Equipment Obsolescence." It focuses on the technical and logistical methods used to determine which parts must be kept in stock, how many are required, and how to manage the risks associated with components that are no longer supported by the original manufacturer.

The scope of this training involves the use of "Criticality Matrices" to categorize spare parts based on lead time, failure probability, and impact on production. Participants will learn how to build a robust spare parts strategy that balances the need for high availability with the financial pressure to reduce inventory value. The course also addresses the proactive management of obsolescence, providing techniques for identifying at-risk systems and developing "Mitigation Plans" such as reverse engineering, lifetime buys, or modernizing equipment.

Coverage includes the integration of spare parts management into the CMMS, the role of "Bills of Materials" (BOMs) in parts identification, and the legalities of third party or "Alternative" parts sourcing. Attendees will explore the concepts of "Vulnerability Analysis" to identify single points of failure in the supply chain. By the end of this course, participants will be able to manage a spare parts program that supports high reliability while effectively navigating the complexities of modern industrial supply chains and aging asset bases.

COURSE OBJECTIVES:

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

• Define and identify "Critical Spares" using a structured risk based approach.
• Implement a standardized "Spare Parts Criticality Matrix."
• Establish optimal "Min-Max" and "Reorder Point" settings in the CMMS.
• Conduct a "Vulnerability Audit" of the current spare parts inventory.
• Develop a proactive "Obsolescence Management Plan" for aging assets.
• Utilize the "ABC/XYZ" analysis for inventory prioritization.
• Manage "Insurance Spares" for high value, long lead time equipment.
• Implement "Reverse Engineering" strategies for obsolete components.
• Evaluate the risks and benefits of using "Alternative" or third party parts.
• Coordinate with procurement to manage "Sole Source" vendor risks.
• Track and reduce the value of "Dead Stock" and "Obsolete" inventory.
• Design a "Kitting and Staging" process for planned maintenance work.

TARGET AUDIENCE:

This course is designed for Materials Managers, Warehouse Supervisors, Maintenance Planners, Reliability Engineers, Procurement Specialists, and Asset Managers.

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.