SPARE PART REDUCTION & OPTIMIZATION
“Balancing Availability, Cost, and Risk to Optimize Spare Parts Inventory and Performance”
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 24 – 28 Nov 2025 | Dubai – UAE | USD 3495 per delegate |
Course Introduction
Managing spare parts inventory is a critical yet often overlooked factor in ensuring equipment availability, minimizing downtime, and controlling operational costs. Excessive spare parts tie up capital, while shortages increase the risk of unplanned outages. Achieving the right balance requires a strategic, data-driven approach to spare part classification, forecasting, and stocking.
This intensive 5-day course equips maintenance, reliability, and supply chain professionals with the tools to optimize spare part inventory levels, reduce waste, and improve service levels. Participants will learn proven methods such as criticality analysis, ABC classification, demand forecasting, and lifecycle cost optimization to streamline spare parts management in asset-intensive industries.
Course Objectives
By the end of this course, participants will be able to:
• Analyze spare parts demand patterns and stock criticality
• Apply best-practice methods to optimize spare parts inventory levels
• Use forecasting, lead time, and consumption data to rationalize stock
• Reduce obsolescence, overstocking, and emergency orders
• Develop sustainable strategies for spare parts reduction and performance monitoring
Why you Should Attend
• Free up working capital locked in excessive inventory
• Enhance equipment reliability and availability through better part planning
• Build coordination between maintenance, procurement, and warehouse teams
• Develop evidence-based stocking decisions to reduce risk and cost
• Align spare parts management with asset lifecycle strategies
Intended Audience
This program is designed for:
• Maintenance & Reliability Engineers
• Spare Parts & Inventory Controllers
• Plant Engineers and Maintenance Planners
• Supply Chain and Materials Managers
• Anyone involved in warehouse management or procurement for MRO items
Individual Benefits
Key competencies that will be developed include:
• Spare parts categorization and criticality analysis
• Demand-based inventory optimization techniques
• Root cause analysis of stock-outs and overstocking
• Planning for long lead-time and insurance spares
• Use of KPIs to improve inventory turnover and service level
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Reduced spare parts inventory costs without impacting reliability
• Faster identification and disposal of obsolete or redundant parts
• Improved coordination between engineering, stores, and procurement
• Stronger data integrity and decision-making for spare part planning
• Enhanced equipment uptime through smarter stocking practices
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Strategy Briefings – Inventory control principles, asset criticality, and stock policies
• Case Studies – Success stories in reducing spare parts cost and improving uptime
• Workshops – Stock analysis, classification exercises, and optimization planning
• Peer Exchange – Group discussions on inventory pain points and solutions
• Tools – Templates for inventory review, criticality scoring, and reorder planning
Course Outline
DETAILED 5-DAY COURSE OUTLINE
Training Hours: 07:30 AM – 03:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Fundamentals of Spare Parts and Inventory Strategy
Module 1: Introduction to Spare Parts Management (07:30 – 09:30)
• Key challenges, cost impact, and cross-functional coordination
Module 2: Spare Parts Classification and ABC Analysis (09:45 – 11:15)
• ABC/XYZ, FSN, VED models for spare parts prioritization
Module 3: Criticality Analysis for Spares (11:30 – 01:00)
• Failure consequence, lead time, and impact-based ranking
Module 4: Workshop – ABC and Criticality Matrix (02:00 – 03:30)
• Participants classify actual parts using a provided dataset
Day 2: Demand Forecasting and Stock Optimization
Module 5: Understanding Spare Parts Demand Patterns (07:30 – 09:30)
• Slow movers, seasonal demand, and stochastic consumption
Module 6: Forecasting Methods for Spares (09:45 – 11:15)
• Simple average, moving average, weighted forecasting models
Module 7: Economic Order Quantity (EOQ) and Reorder Point (ROP) (11:30 – 01:00)
• Calculating optimal stock levels and order quantities
Module 8: Workshop – Forecasting and EOQ Simulation (02:00 – 03:30)
• Participants apply EOQ and ROP to case scenarios
Day 3: Spare Parts Risk Management and Obsolescence Control
Module 9: Managing Critical and Insurance Spares (07:30 – 09:30)
• Long-lead items, single-source parts, and rare failures
Module 10: Controlling Obsolescence and Redundancy (09:45 – 11:15)
• Strategies for write-off, reclassification, or salvage
Module 11: Root Causes of Stock-Outs and Overstocking (11:30 – 01:00)
• Gap analysis in planning, data, and execution
Module 12: Workshop – Spare Part Disposal and Risk Planning (02:00 – 03:30)
• Team exercise to assess risks and obsolescence triggers
Day 4: Process Integration and System Support
Module 13: Integrating Maintenance, Procurement, and Inventory (07:30 – 09:30)
• Master data, BOM accuracy, and workflow standardization
Module 14: Spare Parts KPIs and Performance Dashboards (09:45 – 11:15)
• Turnover ratio, stockout rate, service level, and fill rate
Module 15: Technology Tools and CMMS Integration (11:30 – 01:00)
• Using SAP, Maximo, or Oracle to manage spare parts lifecycle
Module 16: Workshop – Spare Parts KPI Design (02:00 – 03:30)
• Participants create and present a spare parts dashboard
Day 5: Continuous Improvement and Optimization Plans
Module 17: Lean Spare Parts Management (07:30 – 09:30)
• 5S, visual control, kanban, and min-max strategy
Module 18: Inventory Optimization Projects (09:45 – 11:15)
• Redeployment, vendor-managed inventory, and consignment
Module 19: Final Case Study – Inventory Optimization Plan (11:30 – 01:00)
• Group work on spare part strategy for a sample facility
Module 20: Review, Feedback & Action Planning (02:00 – 03:30)
• Participants define site-specific implementation steps
Certification
Participants will receive a Certificate of Completion in Spare Part Reduction & Optimization, validating their ability to analyze, rationalize, and improve spare parts inventory practices in asset-intensive operations.