RELIABILITY-BASED SPARE PARTS & MATERIALS MANAGEMENT
“Aligning Inventory Strategies with Equipment Reliability to Maximize Asset Uptime”
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 24 – 27 Mar 2025 | Doha, Qatar | USD 2995 per delegate |
| 22 – 25 Apr 2025 | Dubai, UAE | USD 2995 per delegate |
Course Introduction
Traditional spare parts management often leads to excessive inventory or critical stockouts, both of which compromise operational performance and increase costs. By integrating reliability-centered principles, organizations can align materials management with maintenance strategies, asset criticality, and failure patterns—leading to more accurate stocking decisions and improved asset uptime.
This intensive four-day course provides participants with a strategic and practical framework for managing spare parts and materials based on reliability, failure modes, and risk. Participants will learn to apply reliability engineering tools, optimize inventory levels, and improve spare parts planning to support maintenance excellence.
Course Objectives
By the end of this course, participants will be able to:
• Classify and prioritize spare parts based on criticality and reliability requirements
• Apply RCM, FMEA, and failure data to optimize spare parts strategies
• Balance inventory costs with asset availability and service level targets
• Align materials planning with preventive and predictive maintenance programs
• Improve spare parts data quality, cataloguing, and lifecycle controls
Key Benefits of Attending
• Reduce inventory costs while improving equipment uptime
• Prevent unnecessary downtime caused by missing or obsolete spares
• Learn how to integrate reliability and maintenance strategies with materials planning
• Gain tools to standardize spare parts data and eliminate duplication
• Enhance coordination between maintenance, operations, and supply chain functions
Intended Audience
This program is designed for:
• Maintenance and reliability engineers
• Spare parts coordinators and materials planners
• Inventory and warehouse supervisors
• Procurement and asset management professionals
• Maintenance planners and operations support staff
Individual Benefits
Key competencies that will be developed include:
• Reliability-based inventory analysis and decision-making
• Spare parts criticality assessment using RCM and FMEA
• Inventory optimization and service level management
• Spare parts data management and codification techniques
• Lifecycle and obsolescence management of materials
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Improved equipment reliability through better spare parts availability
• Reduced stockouts and inventory holding costs
• Enhanced coordination between maintenance and materials functions
• Standardized spare parts catalogues and data integrity
• Greater supply chain resilience and risk mitigation
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Strategy Briefings – Integration of reliability principles with spare parts and inventory planning
• Case Studies – Application of RCM/FMEA to materials management challenges
• Workshops – Spare parts criticality analysis, inventory modeling, and data cleanup
• Peer Exchange – Discussion on maintenance-materials collaboration and best practices
• Tools – Templates for parts classification, reorder analysis, and lifecycle tracking
Course Outline
Detailed 4-Day Course Outline
Training Hours: 07:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Introduction to Reliability-Based Inventory Management
- Module 1: Challenges in Spare Parts & Materials Planning (07:30 – 09:30)
• Typical issues: overstocking, stockouts, poor visibility
• Importance of integrating reliability with materials strategy
• Overview of lifecycle and usage-based inventory - Module 2: Spare Parts Classification and Criticality (09:45 – 11:15)
• ABC/VED/XYZ/FNS classification
• Criticality matrix and failure impact analysis
• Linking parts to functional locations - Module 3: Reliability Concepts for Spare Parts Planning (11:30 – 01:00)
• MTBF, MTTR, reliability vs availability
• Failure curves and spare parts implications
• Maintenance vs materials decision balance - Module 4: Workshop – Spare Parts Criticality Assessment (02:00 – 03:30)
• Hands-on exercise using asset and failure data
Day 2: Reliability-Centered Approaches and Planning
- Module 1: RCM and FMEA in Materials Planning (07:30 – 09:30)
• Overview of RCM principles
• FMEA structure and linking to spare parts needs
• Using reliability tools to inform stocking decisions - Module 2: Forecasting Demand and Usage Patterns (09:45 – 11:15)
• Determining demand for critical, slow-moving, and non-moving parts
• Historical consumption vs failure-based stocking
• Demand-driven MRP and maintenance-triggered ordering - Module 3: Obsolescence and Lifecycle Management (11:30 – 01:00)
• Parts obsolescence risks and strategies
• Managing discontinued and long-lead items
• OEM support and alternate sourcing - Module 4: Workshop – Reliability-Based Reorder Planning (02:00 – 03:30)
• Develop reorder points using MTBF and criticality factors
Day 3: Inventory Optimization and Performance Monitoring
- Module 1: Inventory Cost and Service Level Balancing (07:30 – 09:30)
• Total cost of ownership and holding cost models
• Service levels: target setting and performance
• Safety stock for critical and variable-use spares - Module 2: KPIs and Metrics in Spare Parts Management (09:45 – 11:15)
• Fill rate, stockout rate, turns, and stock coverage
• Tracking and improving materials-related KPIs
• Dashboard examples for maintenance and warehouse leaders - Module 3: Warehouse Integration and Spare Parts Availability (11:30 – 01:00)
• Coordination between maintenance planning and stores
• Staging, issuing, and parts kitting
• Urgent part requests and emergency protocols - Module 4: Workshop – Inventory KPI Analysis (02:00 – 03:30)
• Analyze sample performance data to identify gaps
Day 4: Spare Parts Data, Governance, and Final Integration
- Module 1: Spare Parts Codification and Master Data Management (07:30 – 09:30)
• Standard naming conventions and attributes
• Preventing duplicates and cleansing existing databases
• Use of EAM/CMMS systems for materials management - Module 2: Integration with Maintenance and Procurement (09:45 – 11:15)
• Roles and collaboration across departments
• Linking parts to work orders and BOMs
• Vendor lead times and service agreements - Module 3: Final Review and Action Planning (11:30 – 01:00)
• Recap of key practices and implementation roadmap
• Self-assessment and site-specific application - Module 4: Certification and Wrap-Up (02:00 – 03:30)
• Feedback, Q&A, and action plan discussion
• Certificate distribution and course closure
Certification
Participants will receive a Certificate of Completion in Reliability-Based Spare Parts & Materials Management, confirming their ability to apply reliability principles to inventory and materials planning for optimized asset support and cost performance.