COST REDUCTION TECHNIQUES FOR MAINTENANCE. Our Consultant: Mr. Balachandran

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1 26 & 27 MARCH 2018 THE SAUJANA HOTEL, KUALA LUMPUR Our Consultant: Mr. Balachandran At least 30 40% of operational costs of a manufacturing organization is spent on maintenance activities. Maintenance cost such as spare parts, tools, consumables and modifications could be put into good use if the unnecessary costs were under control. A lot can be done to minimize maintenance costs if the maintenance personnel understand the implication of good PQCDS in the overall cost management in maintenance. This programme is designed to give maintenance personnel the much-needed techniques to eliminate non-value-added activities and work on cost-saving activities.

2 TRAIN INSANE, OR REMAIN THE SAME.

3 INTRODUCTION At least 30 40% of operational costs of a manufacturing organization is spent on maintenance activities. Maintenance cost such as spare parts, tools, consumables and modifications could be put into good use if the unnecessary costs were under control. A lot can be done to minimize maintenance costs if the maintenance personnel understand the implication of good PQCDS in the overall cost management in maintenance. This programme is designed to give maintenance personnel the much-needed techniques to eliminate non-value-added activities and work on cost-saving activities. OBJECTIVES At the end of the programme, participants will be able to: Create an in-depth understanding of maintenance activities and its value to bottom line of an organization; Improve the skills and techniques to identify, measure and manage cost to all maintenancerelated activities; Diagnose the existing performance gap in maintenance work and introduce performance standards to improve for results; and Learn how to identify the different types of wastage in all maintenance-related work and implement waste elimination measures.

4 COURSE CONTENTS DAY 1 Module 1: Understanding Maintenance Operations Maintenance as a strategy to manufacturing vision Element of life cycle cost in a plant How machine reliability and maintenance work is related to productivity Equipment cost to manufacturing Maintenance personnel roles in cost reduction Understanding value-added actions Group assignment and presentation Module 2: General Cost Distribution in Maintenance What is cost and how cost is related to profit? Types of cost related to all maintenance activities (overhead, overtime, breakdown and spare parts) Modification and repair time taken cost Internal failures The cost of poor quality You have a role in controlling cost Module 3: Breakdown Cost Reduction Examining your current maintenance practices in your factory Why equipment failed? 3 cultures in maintenance Breakdown maintenance Inspection and detecting failure Preventive maintenance Objectives of maintenance Strategies for zero breakdowns

5 DAY 2 Module 4: Spare Parts Cost Reduction Where does the money for spare parts come from? Why spare parts fail? Understanding spare parts cost Basic rules and tools for spare parts management Module 5: Maintenance Cost Reduction Techniques Inefficiency reduction and types of tools to improve the situations How to detect failure? What types of failures could be detected early to prevent major lost Overhead cost reduction Overtime cost reduction Measuring maintenance effectiveness Module 6: Waste Reduction Techniques Repair and rework reduction Repair time reduction Set-up time reduction Strategies for waste reduction Summary of learning 60-day action plan

6 OUR CONSULTANT Mr. Balachandran is currently a full time training consultant with over 17 years of solid industrial experiences in the Manufacturing Sector, and 12 years of experience in Maintenance & Manufacturing Trainings & Consultancy. He began his career in the Equipment Maintenance Function in Motorola Malaysia & grew steadily to become an Equipment Engineer. From there he tool on a position as Section Head for a Production Unit which he ran for more than ten years. He moved on to Thomson Audi Electronics in Muar as a Production Manager in 1991 where he spent 2 years handling the plant operations. Subsequently, he assumed a position as a Production Manager & a Training & Education Manager at Samsung Electron Devices, Seremban till July Mr. Bala then switched to work as a management consultant for 7 years and a full time trainer specialized in manufacturing, maintenance & training. His natural leadership style coupled with his experience in various aspects of Manufacturing in 3 different industries makes him especially valuable as a resource person for Human Resource Development in the Manufacturing Sector. Throughout his 12 years of career in training & consulting, he had trained more than 3000 professionals in various fields of the industry. Companies being trained ranges from MNC companies, for instance Samsung Electronic, Minolta, TDK, Matsushita, Robert Borsch, Sony, Swedish Motor Assembly, Komag Malaysia, Western Digital, Motorola, Dell, Texas Instruments etc, to local giants like TNB, Genting Sanyen, Teck See Plastics, HICOM, MAS, PROTON etc. In addition, Mr. Bala is also attached to the Society for Maintenance & Reliability Professionals of U.S.A.

7 26 & 27 MARCH 2018 REGISTRATION FORM IDA Please register the following personnel to attend the training as above Please photocopy for multiple bookings. Name: Designation & Dept. : Office (Direct Line) Mobile Phone: 4 EASY WAYS TO REGISTER Call : Fax : /2 register@iknowledge.com.my Mail : Suite 3A21, Kelana Centre Point, Block A, Jalan SS7/19, Kelana Jaya, Petaling Jaya Selangor, Malaysia TRAINING INVESTMENT Early Bird Registration (Before 26 th February 2018) Early Bird Pricing : RM 2700 per pax (RM 2862/pax incl 6% GST) Name: Designation & Dept. : Office (Direct Line) Mobile Phone: Name: Designation & Dept. : Office (Direct Line) Mobile Phone: Normal Registration Individual Pricing : RM 3000 per pax (RM 3180/pax incl 6% GST) Group Pricing : RM 2800 per pax (RM 2968/pax incl 6% GST) (for 3 pax and above) GST No. : UPCOMING COURSES i. Electronics Troubleshooting ii. Essential AUTOCAD iii. Air Conditioning in Hospitals iv. Emergency Generator Set & It s Maintenance Please contact our sales personnel for detailed of 2018 course calendar COMPANY REGISTRATION POLICY It is important to read and understand our Company Registration Policy before signing or stamping the registration form. You may get a copy of our policy from our personnel or from the link below: Company Name: Contact Person: Designation: Address: Office (General Line): Office (Direct Line): Fax No: Person In Charge: (Finance) (Finance): Contact Number: (Finance) I hereby agree to Asia iknowledge Sdn. Bhd. s Company Registration Policy by signing or affixing the company stamp below: CANCELLATION & PAYMENT POLICY You may substitute the participants any time. No cancellation is allowed upon issuance of confirmation and tax invoice. Payment has to be made prior to training date. PROGRAM POLICY Our consultant & topics are confirmed at the time of publishing. However, circumstances beyond the control of the organizers may occur. Asia iknowledge S/B reserves the right to alter or modify the advertised speakers/ dates/topics if necessary. PAYMENT DETAILS Payment is required within 7 days upon receipt of the invoice. All payment must be received 7 working days prior to the training date. 1. Direct Deposit Company Name: ASIA IKNOWLEDGE SDN BHD Account number: Bank: United Overseas Bank (Malaysia) Berhad, UOBM Damansara Uptown, Ground Floor, No. 1, Jalan SS21/58, Damansara Uptown, Petaling Jaya, Selangor * Please instruct your bank to pay all transfer charges from your account and send in a copy of remittance advice by /fax. 2. Bank Cheque or Bank Draft Payable to ASIA IKNOWLEDGE SDN BHD Authorized Signature Company Stamp