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ME-008

Cost Effective Maintenance

Intensive 5-day course · English, Arabic & European languages

Plant engineers, maintenance directors and operations superintendents study commercial asset management disciplines during this five-day course. Delegates examine total cost accounting, fixed expenditure reduction, risk-based maintenance scheduling, supply chain rationalisation and shutdown execution. The programme establishes practical frameworks for eliminating operational waste without sacrificing equipment reliability, statutory compliance or industrial safety standards.

Classroom

Public courses in our cities

  • 19–23 Oct 2026Manama£3,080 + VAT
  • 2–6 Nov 2026Dubai£4,200 + VAT
  • 16–20 Nov 2026Barcelona£3,080 + VAT
  • 7–11 Dec 2026Paris£3,600 + VAT
  • 21–25 Dec 2026Riyadh£4,200 + VAT
  • 11–15 Jan 2027London£3,360 + VAT
Show 23 more dates
  • 25–29 Jan 2027Riyadh£4,200 + VAT
  • 8–12 Feb 2027Istanbul£2,280 + VAT
  • 22–26 Feb 2027Doha£4,200 + VAT
  • 1–5 Mar 2027Vienna£3,400 + VAT
  • 15–19 Mar 2027Geneva£4,200 + VAT
  • 5–9 Apr 2027Abu Dhabi£4,200 + VAT
  • 19–23 Apr 2027Barcelona£3,080 + VAT
  • 3–7 May 2027Paris£3,600 + VAT
  • 17–21 May 2027Cairo£2,280 + VAT
  • 14–18 Jun 2027London£3,360 + VAT
  • 28 Jun – 2 Jul 2027Jeddah£4,200 + VAT
  • 12–16 Jul 2027Istanbul£2,280 + VAT
  • 26–30 Jul 2027Singapore£4,200 + VAT
  • 2–6 Aug 2027Vienna£3,400 + VAT
  • 16–20 Aug 2027Muscat£3,080 + VAT
  • 6–10 Sep 2027Casablanca£2,280 + VAT
  • 20–24 Sep 2027Barcelona£3,080 + VAT
  • 4–8 Oct 2027Paris£3,600 + VAT
  • 18–22 Oct 2027Manama£3,080 + VAT
  • 8–12 Nov 2027London£3,360 + VAT
  • 22–26 Nov 2027Amman£3,400 + VAT
  • 13–17 Dec 2027Istanbul£2,280 + VAT
  • 27–31 Dec 2027Madrid£3,400 + VAT

Group discount: 2 delegates 20% · 3 delegates 35% · 5 or more delegates 50%

Can't make these dates? We can run this course for your team on dates that suit you. Ask for custom dates · In-house options

Online (live)

With a trainer, on dates to suit your team

This course can be taught live online by a trainer, in English, Arabic or any European language, for one person or a whole team.

£1,850 + VAT

Group discount: 2 delegates 20% · 3 delegates 35% · 5 or more delegates 50%

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Cost Effective Maintenance

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Course overview

Industrial maintenance represents a major operating expenditure, yet indiscriminate budget reductions frequently inflict severe financial damage on processing and manufacturing facilities. When organisations slash fixed maintenance budgets without technical risk analyses, equipment reliability declines, unscheduled downtime surges and unit production costs escalate. Sustainable cost control requires distinguishing genuine operational waste from indispensable asset preservation routines. By conducting rigorous cross-functional spend mapping across labour, spare parts inventory, specialised contractor services and routine inspection tasks, plant leadership can eliminate chronic inefficiencies across operating units without compromising statutory compliance or asset integrity. By targeting the underlying causes of equipment failure, engineering teams lower total lifecycle expenditures while safeguarding production continuity.

Delegates evaluate structured financial models that quantify the hidden costs of lost production, unbudgeted contractor call-outs and recurring breakdown repairs. The syllabus outlines proven methodologies for mapping spending categories, measuring wrench time and optimising contractor frameworks. Delegates learn to replace arbitrary budget cuts with risk-based maintenance strategies that target expenditure directly toward critical production assets.

Sustainable cost reduction aligns maintenance economics with frontline reliability engineering and safety compliance. The curriculum explores the integration of Health Safety & Environment (HSE) governance, risk-based inspection methodologies and disciplined front end loading during major plant turnarounds. Tracking performance through balanced Key Performance Indicators (KPIs) ensures departmental spending remains strictly aligned with corporate profitability goals.

Course objectives

By the end of the course, delegates will be able to:

  1. Define the operational principles and commercial foundations of cost effective maintenance
  2. Calculate the total cost of maintenance for an industrial production plant, including downtime and compliance overheads
  3. Formulate a structured business case to eliminate operational waste while preserving equipment reliability
  4. Deploy structured models of excellence to optimise fixed maintenance expenditures and contractor agreements
  5. Align maintenance expenditure with statutory compliance and cost effective safety standards
  6. Prioritise plant reliability initiatives to achieve maximum availability at minimum operating cost
  7. Integrate maintenance cost reduction strategies with ongoing plant reliability and safety programmes

Target competencies

  • Analysing maintenance costs
  • Developing efficiency improvements
  • Identifying essential maintenance and quality requirements
  • Cost optimisation
  • Maintenance planning
  • Reliability improvement

Who should attend

This course suits:

  • Maintenance managers and maintenance supervisors
  • Maintenance planners and schedulers
  • Reliability engineers and plant condition monitoring specialists
  • Project managers and project engineers delivering capital modifications
  • Operations managers and production shift supervisors
  • Engineering professionals preparing for asset leadership roles
  • Specialist contractors supporting client plant maintenance and shutdowns

Training methodology

  • Technical lectures and structured presentations introduce maintenance cost accounting models, spend mapping frameworks and risk-based decision tools.
  • Delegates participate in practical group exercises, video reviews, real-world case study evaluations and peer discussions to design site-specific maintenance improvement plans.

Course modules

  1. Module 1

    Module 1: Understanding the total cost of maintenance

    • Definition and commercial scope of the total cost of maintenance
    • Industrial benchmark standards across manufacturing and processing sectors
    • Identifying authoritative sources of best practice in maintenance economics
    • Core components of fixed maintenance operational expenditures
    • Quantifying the direct and indirect costs of lost production availability
    • Commercial and legal liabilities arising from regulatory non-compliance
    • Mechanisms through which maintenance activities create business value
    • Establishing a balanced approach to defining cost effective maintenance
    • Identifying organisational stakeholders who influence maintenance spending
    • Shifting departmental spending behaviours from reactive purchasing to disciplined procurement
  2. Module 2

    Module 2: The modern maintenance strategy

    • Historical evolution of industrial maintenance strategies and asset stewardship
    • Identifying high-return maintenance investments versus common areas of wasted capital
    • Strategic role of planning and scheduling in controlling site costs
    • Interdependence between fixed expenditure levels and asset availability
    • Shifting maintenance paradigms away from traditional compromises
    • Moving past trade-offs between cost reduction, reliability or safety
    • Unifying cost reduction, asset reliability and workplace safety objectives
    • Aligning contemporary maintenance strategy with enterprise asset management
    • How pace setters generate value through maintenance innovation and operating integration
  3. Module 3

    Module 3: The basics of fixed cost reduction

    • Categorising primary maintenance expenditure streams across materials and labour
    • Process mapping methodologies for maintenance costs
    • Conducting root-cause analyses on recurring budget overruns
    • Operational pitfalls and risks of managing maintenance budgets by statistical averages
    • Structuring a multi-year maintenance cost reduction programme
    • Defining Key Performance Indicators (KPIs) to sustain budget discipline
  4. Module 4

    Module 4: Focus areas for fixed cost reduction

    • Systematic identification and elimination of maintenance workflow waste
    • Distinguishing cost profiles across reactive, preventive and condition-based maintenance
    • Common organisational causes of maintenance labour and material waste
    • Role of detailed work package planning in reducing job costs
    • Principles and practical application of risk-based maintenance regimes
    • Enforcing technical maintenance standards to prevent rework
    • Efficiency improvements achieved through smarter task scheduling
    • Identifying high-yield operational efficiency opportunities across workshops
    • Raising technician tool time and wrench time on operating plant
    • Refining maintenance execution procedures and job safety protocols
    • Adopting lean maintenance practices proven in other industrial sectors
    • Structuring and executing an effective planned maintenance regime
    • Controlling supply chain overheads and inventory carrying costs
    • Contractor engagement strategies and performance-based service contracts
    • Spare parts rationalisation, vendor management and materials control
    • Purchasing strategies for plant equipment and hired engineering services
  5. Module 5

    Module 5: Plant performance and reliability improvement

    • Model of excellence for sustainable plant reliability improvement
    • Formulating a phased site reliability roadmap
    • Ensuring reliability initiatives remain commercially efficient as well as technically effective
    • Evaluating distinct maintenance types against equipment failure modes
    • Measuring asset productivity through Overall Equipment Effectiveness (OEE) and availability metrics
    • Engineering interventions that extend physical asset operating life
    • Capturing lessons learned from historical machinery breakdowns
    • Operational responsibilities of production operators in autonomous asset care
    • Selecting maintenance regimes that raise throughput while lowering unit costs
  6. Module 6

    Module 6: Cost effective Health Safety & Environment (HSE)

    • Business value and risk protection derived from disciplined Health Safety & Environment (HSE) management
    • How poor safety practices generate unnecessary operational and legal expenses
    • Integrating HSE compliance directly within the broader maintenance programme
    • Fulfilling statutory occupational safety and environmental mandates
    • Principles and deployment of risk-based inspection (RBI) methodologies
    • Reducing the administrative cost of regulatory compliance through structured verification
  7. Module 7

    Module 7: The importance of shutdown management

    • Origins and industrial development of the shutdown model of excellence
    • Visual framework outlining the essential components of turnaround success
    • Sub-elements governing turnaround scoping, logistics and contract control
    • Detailed operational blueprint for successful plant outage management
    • Strategic front end loading principles and long-lead planning milestones
    • How pace setters deploy structured stage-gate processes to control outage scope
    • Establishing rigorous quality assurance and workplace safety controls during shutdowns
    • Defining the turnaround organisational structure and governance roles
    • Turnaround materials logistics, workspace coordination and staging
    • Outage execution management, daily progress tracking and post-turnaround reviews

Certificate

Every delegate who completes the course receives an ARUK Training Certificate of Attendance.

Frequently asked questions

How do I register?

Choose a date and city in the schedule and press Register, or send us an enquiry. Our team confirms your place and sends an invoice.

Are fees shown with VAT?

Fees are shown per delegate and exclude VAT, which is added to the invoice where applicable.

Can this course be delivered for our team only?

Yes. Any ARUK course can be delivered in-house at your premises, in a meeting room we book for you, or 1-to-1.

Is this course available online?

Yes. We run it live online with a trainer, on dates that suit your team, for £1,850 + VAT per delegate.

Is there a group discount?

Yes. 20% for 2 delegates, 35% for 3 delegates and 50% for 5 or more delegates on the same course.

Can the course be delivered in Arabic or another language?

Yes. Our courses can be delivered in English, Arabic or any European language, by a trainer who teaches in that language. Mention your preferred language when you register or enquire.

What certificate will I receive?

An ARUK Training Certificate of Attendance.

Related courses

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Cost Effective Maintenance

Key booking terms (read before you register)
  • The full fee is paid in advance, before the course starts.
  • Cancel in writing 30 or more days before the start date (45 for in-house) for a refund. Later than that, the full fee is payable.
  • No refund for non-attendance or partial attendance.
  • Places are for the named delegate only; another person cannot attend instead.
  • Moving to another date or city is only possible if ARUK agrees in writing.
  • Travel, accommodation and visas are your responsibility. A refused visa does not change the cancellation terms.

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Cost Effective Maintenance