Maintenance Cost Reduction – Drivers, Measuring and Optimizations – 3 Day Seminar

 

Location

Seminar will be conducted on customer site, including BQR examples and Best Practices. It can be customized for special customer requirements and examples.

 

Cost

Cost depends on number of participants, customer requirements and location. For a quote please contact BQR.

 

Description

Maintenance cost monitoring is the key for a successful maintenance cost reduction plan.
Many organizations do not properly account for all the maintenance cost drivers. This leads to an incorrect maintenance cost map that does not identify significant cost drivers, and generates faulty decision making. Once an organization understands all maintenance cost drivers and optimization methods, an effective maintenance cost reduction plan can be established.

The seminar is useful for any organization that wishes to explore new maintenance cost reduction plans or investment in IT software. The insights you will gain in the seminar will help you create an optimal plan for maintenance cost reduction. During the course, participants will practice all seminar topics using hands-on examples.

 

Who should attend

Managers and engineers in the field of maintenance, reliability, finance, engineering, R&D, etc.

 

Applicable industries

Wind Power, Energy, gas & oil, trains, automotive, aerospace, defense, etc.

 

Seminar Content

• How to maintain facilities more cost-effectively
• How to save costs with existing resources
• What are your maintenance cost drivers are and how to control them
• How to take the right decision at the right time
• How to move from unplanned stoppages to planned maintenance
• How to increase facilities productivity on time
• What are your direct and indirect maintenance cost drivers
• How to quantify maintenance cost drivers
• The effect of down time on cost
• The effect of unreliable components
• The effect of operational parameters such as: temperature, pressure and cleanliness on failure rates

At the end of the seminar, participants will gain an understanding of cost drivers, which will lead to improved decision making relating to maintenance cost reduction.

 

Instructors

1. Mr. Yizhak Bot, BQR’s Chief Technical Officer and BQR’s head consultant
2. Dr. Amir Segal, BQR’s RAM & ILS manager

 

Seminar Details 

Day 1: Correct use of data and the main cost drivers

a. Data treatment, management and behavior.

i. Input data (required for modelling asset behavior and costs).

ii. Asset maintenance breakdown tree.

iii. Calculating component failure probability distribution functions (in pdf format).

iv. Receiving correct transportation and logistics behavior such as:

a. Procurement and repair times

b. Existing component stock

v. Performing the right maintenance tasks for each component

vi. Allocating the required resources for each task

vii. Follow existing maintenance policy

a. Inspections

b. Preventive maintenance

viii. Best practice data sources:

a. External databases

b. Simulation tools

c. Vendors recommendations

ix. Analyze operational data:

a. Field failures and maintenance history

b. Sensors or manual inspections results

c. Experience

b. Understanding maintenance cost drivers

i. Direct cost – Costs related to maintenance tasks as following:

a. Maintenance tasks (inspections, repairs…)

b. Manpower

c. Facilities

d. Support equipment

e. Spares cost

i. Initial spares for repair / procurement duration

ii. Lifetime spares for discarded components (e.g. filter)

iii. Lifetime spares for condemned components

f. Transportation cost

i. Shipping from OEM

ii. Shipping to repair shops

iii. Back and forth to stock warehouses

 

Day 2: Asset behavior and maintenance modelling including Pareto reports

a. Understanding maintenance cost drivers (continued)

i. Indirect cost – Costs which arise as a byproduct of failures

a. Downtime

i. Loss of production leading to loss of potential revenue

b. Collateral damage

i. Breakage of one machine affecting nearby systems

c. Reputation

i. Failure to meet production deadlines, negative publicity

d. Environmental penalties

i. Breach of regulations, increased toxic emissions

b. Asset behavior and maintenance model:

i. Use input data in order to calculate the stochastic asset behavior

a. Component failures leading to corrective maintenance

b. Inspections and preventive maintenance tasks

c. Wait time for spare parts

d. Downtime

ii. Summing up all direct and indirect costs related to asset behavior

c. Pareto report example:

i. Wind farm Life Cycle Cost over 20 years.

ii. Identifying main cost drivers

iii. Understanding how to achieve cost reduction

 

Day 3: Methods and steps for maintenance cost reduction

a. Step 1: Model asset performance and maintenance cost drivers (as discussed above). Using Pareto reports, identify the leading cost drivers.

i. Input data: Component failure distributions, maintenance tasks, maintenance resources, inspection schedule, logistics

ii. Calculate LCC

b. Step 2: Consider alternative maintenance policies and their effects on asset performance and maintenance cost.

i. Options:

1. Manual search process

2. Automatic: Smart search algorithm

ii. Level of Repair Optimization: Which items to repair and which to discard? Transportation routes, preferred vendors and repair shops

iii. Preventive maintenance and inspections: What is the optimal schedule for pro-active maintenance?

iv. Spare and resources optimization: How many spare parts and shop resources to hold?

c. Using the wind farm example, participants will see how the life cycle cost decreases by more than $230M.

 

Register today at info@bqr.com