Certificate In Managing Maintenance Spares

Certificate In Managing Maintenance Spares Specifically Designed To Help Maintenance Departments Achieve Critical Success Of A Smooth, Cost Effective And Timely Supply Of Spare Parts 19 – 22 May 2013 Dusit Thani Hotel, Dubai, UAE Your Expert Course Director

Ben Stevens

Top 3 Benefits Of Attending 1. Learn how to get the right spares to do the right job at the right time – Use the most effective tools for spares management and apply the most effective practices to your own workplace 2. Understand and apply KPIs to ensure that the supply of spares meets your organisation’s criteria of cost-effectiveness 3. Build your Personal Development Plan for use at your workplace

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The George Washington University School of Business, IIR Middle East’s Academic Partner, is dedicated to excellence: in its teaching and research about management, in the public and private sectors, within the United States and internationally.

The school has a 75 year history of preparing men and women for leadership in both the public and private sectors. Known internationally for its dedication to academic excellence, the school draws students from all parts of the United States and around the world.

Beyond first class teaching and scholarship, the school’s faculty offers practical experience in the issues and challenges confronting business and government. Its research centres link faculty and students with US and international business and government organisations. Recent distance learning initiatives have expanded the school’s global reach.

Course Requirements And Certificates Delegates must meet two criteria to be eligible for an IIRME/GW Certificate of Completion for a course: 1. Satisfactory attendance – delegates must attend all sessions of the course. Delegates who miss more than 2 hours of the course sessions will not be eligible to sit the course exam 2. Successful completion of the course assessment Delegates who do not meet these criteria will receive an IIRME Certificate of Attendance. If delegates have not attended all sessions, the Certificate will clearly state the number of hours attended.

Who Should Attend?

This course is a must-attend event for: • Managers, Senior Technicians and Supervisors of spares management and warehousing • Operations, Design, Mechanical, Electrical and Instrumentation Engineers • Logistics, Procurement, Buyers, Expeditors involved in spares acquisition • Planners, Schedulers, Reliability Engineers responsible for maintenance work • Supervisors from Operations, HSE, HR, Finance, QA, Inspection

T: +971 4 335 2437 F: +971 4 335 2438

Meet Your Expert Course Director Ben Stevens has led many successful maintenance conferences and seminars with IIR ME throughout the Gulf region over the past decade. He has been running his own company, DataTrak Systems Inc., since 1984 with a concentration on maintenance management and reliability. From 1995 to 2002 Ben was on a full time contract with PricewaterhouseCoopers International Centre of Excellence in Physical Asset Management, working closely with CMMS vendors. During 2003 to 2011, he was President of OMDEC Inc – a Canadian company in the forefront of reliability and maintenance innovation.

Prior to his work in the maintenance field, he was trained as an economist and practiced as a financial manager – including CFO and CAO in several manufacturing companies. Ben has delivered hundreds of training programmes and delivered maintenance consulting projects in a wide range of companies in 25 countries. His sessions are focused around his own experience on which he bases the mini-workshops and case studies, which consequently relate directly to the practical workplace. He has developed numerous innovative approaches linking reliability and maintenance management to finance – focusing on the definition, and delivery of risk and value in maintenance.

Read What Delegates Have Said About Ben’s Previous Courses With IIR ME: “Ben explained ideas related to the delegates’ working environment. The course added value that can be implemented in the maintenance department in my workplace. Each session was enriched with Ben’s experience, case studies and presentations.”

Muhannad Mohamed Ali Bu Haji, Transco Abu Dhabi Transmission and Dispatch Company, UAE

“Ben has wide knowledge in all different types of maintenance management. Because of his experience it was really easy for him to understand my learning needs. He used various case studies and shared his previous work experiences with us.”

Khalid Al Bathi, General Authority of Civil Aviation, KSA

W: www.iirme.com/spares

Certificate In Managing Maintenance Spares 19 – 22 May 2013 • Dusit Thani Hotel, Dubai, UAE Course Timings Registration will be at 07:30 on Day One. Course sessions will start promptly at 08:00 and end at 14:30. There will be two short breaks for refreshments and lunch will be served at the end of each day’s sessions.

Course Overview This course provides a solid grounding in the critical importance of smooth, cost-effective and timely supply of spare parts. Delegates will explore the various types of spare parts and the tools used for effective spares management. Using practical examples, delegates will discuss best practices and newly developed advanced spares management concepts.

Delegates will also learn the principal ways to forecast spares. A central theme throughout will be on financial KPIs to ensure that the supply of spares meets the organisation’s criteria of cost-effectiveness and reliability.

Course Outline Day One Introduction To Spare Parts Management Around the world almost all businesses and their maintenance staff see the same problem – how to get the right parts at the right place at the right time. In this first session, delegates will lay the groundwork for the course by exploring the basics of spare parts management. This introduction will place the emphasis on good management techniques,

Deciding on the “best” level of spares is a key issue – too much and the finance department wants to cut back; too little and the operations department will not stay in business; and the wrong spares means the maintenance department cannot do their job. In the last few years, an impressive number of tools have been perfected which greatly assist in the effective management of spares; this course will explore these and provide you with the opportunity to see the advantages and pitfalls of these tools. Prominent among these is the EAM/CMMS – with its automated and built-in functions for economic order quantities, minmax levels, costing etc.

Behind the effective supplying of store to the job site are the spares’ procurement and warehousing processes; do these right and many challenges disappear. Using practical examples, this course will familiarise you with the best practices and how they can be introduced and maintained. Demand forecasting is the other part of the equation; here you will learn the principal ways to forecast spares – based on historical consumption plus future operations, based on reliability of components, and based on the required reliability of the plant.

Finally, you will be introduced to some of the more recently-developed advanced spares management concepts. This will focus strongly on building action plans that can be taken back to your workplace for the benefit of your organisation. You will explore in detail the service level and financial KPIs that are essential for measuring the effectiveness of your efforts – thus ensuring that the supply of spares meets the overall organisation’s criteria of cost-effectiveness.

definitions and best practices. Later in the course, each will be expanded into the rules for continuous improvement. This session will end by examining the pluses and minuses of who should manage spare parts and why. The topics you will cover are: •

Why stock spare parts – why not Just In Time spares provisioning by the vendor?

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Types of spares – consumables, free issue spares, repairable spares, tools etc – why do they matter?

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Defining critical spares and how to manage them effectively

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Definition and treatment of capital spares, rotable spares, high value components

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Physical management vs. financial management – how to rationalise the difference?

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Effective spares management – introduction to spares’ KPIs and service levels

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How to determine the “right” spares’ levels

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Who’s in charge? Responsibility for spares – the warehouse, or the technician? Or maybe even finance? How to decide?

Key Tools In Spare Parts Management Once the basics have been established, you will start to apply the tools needed to effectively manage spare parts. But the tools will not work unless the maintenance team is able to apply them. In this session, you will be introduced to the main tools and then become familiar with them through practice – plus the techniques and processes needed to keep them effective. The focus will be especially on work planning and inventory planning – and how they must go hand in hand. The key tools

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The in-house training division of IIR Middle East Tel: +971 4 407 2624 • Email: CTS@iirme.com www.iirme.com/cts

Best practices in spare parts management – and how to use them The EAM/CMMS – the #1 tool for spares management

•

The role and use of the Work Order (WO) and WO pick lists

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Practical inventory planning – using min-max spares levels and safety stock, EOQs to set the inventory requirements

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The EAM/CMMS – what data do we really need?

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Using the EAM/CMMS – automatic requisitions, POs and how to use them to improve spares management

T: +971 4 335 2437 F: +971 4 335 2438 E: register@iirme.com W: www.iirme.com/spares

Day Two Physical Management Of Spares In this session, you will focus on the key steps in the physical management of spares and ensuring that what is in the warehouse is accurately reflected in the inventory records. Starting with some simple but effective methods of improving materials performance, you will then review the record keeping necessary for on-going performance delivery.

Next we turn to the different types of warehousing and supply – and the advantages and advantages of each. In each case the emphasis will be on practical applications that can readily be brought back to your

Subjects to be included are: •

forecasted •

Shelf life, delivery routes, kit-ups, emergency repair kits and other practical devices for inventory service improvement

•

Keeping track – the record keeping that matters – receipts, issues, returns, quarantine, rejects

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Staying on track – inventory counts, ABC analysis and reconciliations

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Warehouse management – multiple warehousing, inter-warehouse transfers and how to manage them effectively

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Best practices in managing staffed vs. unstaffed warehouses – how to make sure the records reflect the actual numbers on the shelf

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Managing in-house vs. contractor supplied spares

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Vendor-managed inventory – does it work? Who pays for it?

Financial Management Of Spares Like it or not, the finance department will always keep a close watch on the level of spares. In this session, you will explore the reasons for this – with emphasis on the financial KPI that are typically used to measure effectiveness. At the same time, you will find out that these financial KPI all too frequently miss the key issues related to the costs of spares

Factors which affect future spares demand – and how better planning will refine the forecasts

•

Interpreting historical spares consumption – can the past consumption be used to forecast future needs?

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Reliability based sparing – understanding the basics

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Equipment and component reliability and spares lead times – how they must inter-relate; and how they must impact on procurement

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Reliability-based spare management – introduction to SMS (a specialised Spares Management System)

workplace. Topics to be covered are: •

Which spares should be forecasted? And which do not need to be

KPIs And Other Performance Measurement Tools Key Performance Indicators are extensively used to measure results – maintenance and spares Management are no different. You will explore the most important of the many KPI that are routinely applied to maintenance spares. The initial focus will be on understanding the data collection, analysis and expected results of these KPI. You will then examine the advantages and deficiencies of these measures, and more specifically, what actions should follow the publishing of the results. You will cover the following topics: •

Practical KPI for spares – including service levels, turnover, materials usage efficiency, materials costs per work order etc.

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How to select, develop and use effective KPI – Which to focus on and which to ignore

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How good spares management will help to improve standard Maintenance KPI such as MTBF, MTTR etc

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Measuring vendor performance and their impact on spares supply

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Does tracking parts standardisation help? – Practical examples

stock-outs. Resolving this difference will be a key result of the day.

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Why financial management of spares gets so much attention – the impact of spares on business success

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Key inventory and spares’ financial measures – and how they miss vital issues

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Costing spares – various methods such as LIFO, FIFO, average cost

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The hidden cost of spares – how to manage and reduce them

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Expensing costs vs. inventorying costs

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Spares outages – practical examples of how to calculate their true cost

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Alternatives to spares stock-outs – delaying, expediting, scavenging, re-installing – the dangers and costs of getting it wrong

Day Three Forecasting Spare Parts Requirements In the first session of the day, you will be exposed to the practices and the processes that are essential to smart planning and execution of maintenance work. In the final part of this session, attention will turn to requirement forecasting methodologies. Primary among these will be introducing the use of required levels of plant and equipment reliability as the basis for determining effective inventory levels. In this advanced session, attention will turn to how reliability and failure forecasting can be used to sharpen our understanding of replenishment forecasting.

Day Four Advanced Spares Management On the final day you will step through numerous practical examples of how you can improve maintenance performance with some advanced spares management techniques. The focus will be on how these practices can be taken back to your workplace and effectively implemented. In each case, the advantages and possible pitfalls will be examined, along with the best practices. This session is designed as an advanced practical session which can nevertheless bring substantial value to the maintenance function.

•

Planning your spares improvements – where to start, where to focus priorities

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Understanding, valuing and resolving “Waiting for Spares”

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12 key steps to better spare parts management – and extensive and practical case study

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Making sure maintenance gets the right spares (and not cheap substitutes) – making the compelling case for quality

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Budgeting for spares – and how to make sure your budgets do not get reduced

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Spares and risk – practice in how to calculate the probability and the cost of a stock-out

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Radical spares reductions – the process of minimising overall spares investments and evaluating the risks

T: +971 4 335 2437 F: +971 4 335 2438 E: register@iirme.com W: www.iirme.com/spares

Certificate In Managing Maintenance Spares 19 – 22 May 2013 • Dusit Thani Hotel, Dubai, UAE FIVE WAYS TO REGISTER IIR Holdings Ltd. P.O Box 21743 Dubai, UAE

+971 4 335 2437 +971 4 335 2438 register@iirme.com

www.iirme.com/spares

DISCOUNTS AVAILABLE FOR 2 OR MORE PEOPLE CALL – 971-4-3352483 E-MAIL – a.watts@iirme.com Event Certificate In Managing Maintenance Spares 19 – 22 May 2013

BC5097

Course Fee Before 3 March 2013

Course Fee Before 24 March 2013

Final Fee

US$ 3,895

US$ 4,395

US$ 4,695

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Course fees include documentation, luncheon and refreshments. Delegates who attend all sessions and successfully complete the course assessment will receive an IIRME/GW Certificate of Completion.

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