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Plant Maintenance
Cost Reduction Strategies
7 - 11 November 2016, Kuala Lumpur

Industrial plant and equipment are designed and optimally operated to achieve business objectives.
Effective operation of plant and at the same time maintaining costs at lower levels without jeopardizing
risks is vital.
The plant operational budgets are huge and variable, if not planned and monitored in a professional
manner. Among them maintenance and energy costs are key runners. Reliable operations and
maintenance are paramount to overall effectiveness of business objectives ensuring minimum downtimes
and maintenance cost optimization. The variety of equipment such as gas turbines, HRSGs, boilers,
steam turbines, generators, heat exchangers and fired heaters bring certain complexities when identifying
problems and conducting the specific maintenance requirements. This program is designed to assist the
maintenance management, technicians and engineers in identifying the various equipment design and
operating performance, functional parameters, reliability considerations and reliability tools as part of RCM
Program development and implementations, criticalities and failure modes, consequences and those
mitigation characteristics which will result in cost reductions.
This course is a 5 days highly interactive practical program with focus in depth into various cost factors
associated with plants and best operating procedures for reducing operation cost. Specific discussions on
risk and reliability based maintenance management approach with best condition based approach
discussions on condition monitoring technologies will supplement the course. Plant and equipment bad
actors management programs with emphasis on trips, performance variations, production load cycling and
its effects and turn around work-scopes optimization techniques aimed at reducing costs with case studies
will be presented. A thorough insight into the current maintenance and reliability practices GAPS and
resolution, maintenance cost and life cycle analysis , Remaining Life Assessments, evaluations and
recommendations and equipment repair and replacement decisions as part of plant and equipment
objectives will be discussed in depth. The asset management model as applied to plant equipment as part
of RCM strategies will also be discussed in detail with reference to PAS-55 / ISO 55000 / AIM cost
reduction recommendations for plants.
The course is useful for all maintenance personal, including management, with its detailed
coverage of reliability tools and cost optimization.
Maintenance Superintendent, Petrochina International (Bermuda) Ltd
An eye opener to someone who is new in realiability field. More depth in reliability was discussed
over things engineers normally missed at plants.
Reliability Assistant Manager, Teknik Janakuasa Sdn Bhd

Tel: +65 9743 4606

Fax: +65 6271 9029

Email: linda@tun.sg

www.tun.sg

About The Trainer

S. Nadeem Ahmed has more than 20 years of industrial experience with career as a
Mechanical Engineer with Manufacturing and Engineering MRO Industry. He is
experienced in Maintenance, Repair & Overhaul (MRO), Testing and Evaluation of
Turbo Machinery including Aero and Aero derivative Gas Turbine Power Plants. He has
worked with various concerns on life extension and evaluation of 1400 MW+, combined
cycle power plants and 1600MW+, Thermal Power Plants.
Nadeem has also provisioned Process companies (Power Generation, Oil and Gas etc) on Effective
Reliability Improvement Programs, Maintenance Management Strategies, Lean Maintenance and Six
Sigma Process Improvement Strategies integrating the same with reliability solutions.
He holds a Masters in Mechanical Engineering with Major in Thermal Power Systems Engineering, is a
Certified Six Sigma Master Black Belt from USA & is well versed with the Quality, Six Sigma and Power
Plant Equipment Reliability Analysis Softwares. He has also conducted training for the following
companies: PTT Global Chemical Public Company Limited, HMC Polymers Company Limited, Teknik
Janakuasa SDN BHD, Petrochina International (Bermuda) Ltd, Abu Dhabi Marine Operating Company,
Abu Dhabi Company for Onshore Petroleum Operations, Dubai-Water and Power, Alstom Malaysia,
Belzona Indonesia, PPTEP Thailand and Johar Coal Fired Power Malaysia.

About The Organizer

T.U.N International was formed with the objective of truly understanding the
needs of each individual organizations training requirements. Our strength lies
in our ability to listen to our clients, understand their unique business issues
and assisting them to deliver the appropriate training solution based on the
business challenges in thecurrent market situation.
Our vision is to be the No. 1 preferred training provider for all corporate companies by providing an
innovative approach to your training requirements. We facilitate a training solution that is not only cost
effective, but tailored to yield maximum benefits.
We deeply value our working relationship with our clients and constantly dedicate ourselves to exceed your
expectations of us. Besides customizing in-house training solutions for corporate companies, we also offer
public courses and conferences in
various industries.
T.U.N In-house Training Solutions
Save up to 40% when you use T.U.N In house Training Solutions to customize in-house training programmes
for your organization. Tailor-made training courses, at a venue of your choice and a time convenient to you
and at a fraction of the cost. For more information on T.U.N In-house Training Solutions, please contact Ms.
Linda Teo at +65 6376 3178 or email: linda@tun.sg

Tel: +65 9743 4606

Fax: +65 6271 9029

Email: linda@tun.sg

www.tun.sg

Plant Maintenance Cost Reduction Strategies

7 - 11 November 2016, Kuala Lumpur

Course Benefits

Plant Operational Costs understandings

Maintenance Strategies and Cost elements
Reliability importance in cost reductions
Failure reductions & Failure Analysis
Man-hours Management in Maintenance
Plans.
Subcontracts Costs in Plant day to day
operations
Understanding Reliability Performance and
Functions GAPs in a Plants
Understanding the Design Concepts of
Equipment / Plants
Plant / Equipment Major Checks , Critical
Equipment Plans
Equipment performance Evaluation
throughout life Cycle
Understanding Life Extension Evaluation
and Recommendations
Understanding Equipment Key Maintenance
Cost performance Indicators
Plants / Equipment Bad Actors
Management, Analysis.
RCM based Reliability Program
Development and Implementation
Guidelines.
Maintenance Criticality Analysis for cost
monitoring
Systems & Equipment Repair vs.
Replacement decision
Improved job performance, decision making
capabilities.
Technology transfer between participants

Learning Objectives
After completing this course, participants will be able
to understand:

Who Should Attend

Plant Maintenance Management

- Managers
- Engineers
- Chief Engineers
- Vice Presidents
Maintenance Staff
Maintenance Planning Managers
Maintenance Program Engineers
Reliability Engineers / Managers
Design Engineers / Staff
Technicians
Finance and Procurement Managers

Tel: +65 9743 4606

Fax: +65 6271 9029

A-Z of Industrial Plant and Equipment

Equipment / Plant Basic Classifications and
cost elements
Equipment / Plant Performance and Functional
Standards
Advance Maintenance Management in Plant
with optimized costs
Eliminate unplanned down time, Improvement
in maintenance program
Latest innovations in RCM, FRCA and CM for
Modern Equipment / Plants
Implement Solutions that reduce the cost per
hour of operation
Increasing daily revenue for Equipment / Plant
Optimize performance and efficiency by
adopting updates in condition monitoring
Constant review of Maintenance and reliability
strategies for cost optimizations
Review of LTSA , LTPA etc

Training Methodology
The training will be facilitated using modern
techniques, supported by case studies from real
Equipment / plant environment and videos. The
Analysis tools application to plant / Equipment
maintenance, reliability, and failure cost analysis will
be exercised with mini workshop within the
sessions. Participants may be requested to bring
their laptops to exercise analysis software with their
own plant data. Repair vs. replacement decisions
on specific equipment will be exercised during the
course.

Email: linda@tun.sg

www.tun.sg

Plant Maintenance Cost Reduction Strategies

7 - 11 November 2016, Kuala Lumpur

Day 1
Industrial Plant Introduction

Plant design and Operational Objectives

Plant Layout , Systems , Equipment etc

Documents, procedures, manuals etc.

Cost Breakdowns in Plant Operations and

Maintenance.
Maintenance strategies, Methodologies and
Philosophies.

PMs , CMs , PdMs, Proactive

RCM, TPM, Condition based .

Cost Effectiveness

Decision on Strategies for Equipments

Rotating, Static and BOP.

Examples
Day 2
Plant Equipment Criticality Analysis

Plant equipment failures

Criticality Criterias , Use of softwares

Operational , safety , Quality and Environmental

Failure rates MTBF, Maintainability MTTR & Repair

Costs.

Variations & Risk Charts

Criticality Analysis exercise

Risk and Reliability Management ( Cost reduction
Approach )

RCM Reliability Centred Maintenance (Cost Model)

RBI Risk Based Inspection

(Integrity Operating Window)

SIF , SIL and SIS understanding

RMF reliability Management Framework

o Team formations
o Structure and responsibilities

Cost Focused reliability

Maintenance Efficiency and Effectiveness

Case study

Day 4
KPIs and Plant Cost Monitoring

Plant Availability and Costs variations

Equipment Failure Cost Analysis

Routine and Non Routine KPIs

Maintenance Index calculations

Operating Margins (Performance Vs Costs)

Inventory ratio Variations

KPIs Hierarchy / Costs KPIs

Operational & Maint. KPIs

Plant Condition Monitoring Strategies

Cost reductions through Effective Condition

Monitoring

Operational and Process Monitoring

Equipment CM Parameters

Avoiding Over-scoping in CM decisions

Effectiveness of CM skills

Case studies
Day 5
Plant Subcontract and Services Costs

Subcontract repair costs Analysis

LTSAs , LTPPA , LTSS agreements

Parts Provisioning , Vendor Cost Evaluations

Vendor Quality Compliance and Cost Impacts

Contract Request Documents & Cost Evaluation

Plant Budgets Planning

Planned vs Actual

Variances monthly , quarterly , yearly

Shutdown / Turn-Around budgets

Routines Vs Non Routines

Discussions on SAP Plant maintenance & Cost

Modules

Conclusions

Day 3
Cost reduction Strategies / Maintenance Cost Factors

Maintenance Quality (rework ratios)

Maintenance Materials and Tools

Man-Hours consumed

Work-scoping of Plant equipment

Shutdown and Turn-Around scopes

Inventory policy / Management

Typical case study

Data Analysis and Requirements (Costs Understandings)

Operations , process and Maintenance Data

Equipment Specific Functional and Performance data

Cost data and Integration with reliability targets

Cost variance PM/ CM , Work Orders , Costs

Equipment category Specific CAPEX / OPEX

Budgeting and Costings

Use of Six Sigma Anlaysis Tools

Tel: +65 9743 4606

Fax: +65 6271 9029

Email: linda@tun.sg

www.tun.sg

Plant Maintenance Cost Reduction Strategies

7 - 11 November 2016, Kuala Lumpur
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Plant Maintenance Cost Reduction Strategies,

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7 - 11 November 2016, Kuala Lumpur

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COURSE
Plant Maintenance Cost Reduction
Strategies
7 - 11 November 2016, Kuala Lumpur

EARLY BIRD

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