MCP Workshop Part 1: Cutting Maintenance Costs
On Tuesday, MCP hosted a focused and engaging workshop in Reading, designed to tackle a challenge common across many sectors – how to reduce the cost of maintenance while improving operational performance. With representatives from various industries in attendance, the event offered a lively forum for practical insight, discussion and shared learning.
The Session at a Glance
Led by Paul Deighton, a Certified Maintenance & Reliability Professional with over four decades of experience, the workshop drew on lessons from more than 6,000 asset management assessments conducted by MCP. This was no lecture – it was a highly interactive session, built around real-world scenarios and audience participation.
The core message? Maintenance costs can be significantly reduced through two often-overlooked levers:
Both areas were explored in detail, with practical advice and proven strategies offered throughout.
Workshop Highlights
1. Maintenance Planning & Scheduling
This section demonstrated how labour utilisation and productivity can be improved by planning tasks in advance and scheduling work based on skills, availability and priority. Delegates learned how:
Spares kitting reduces downtime before tasks even begin.
Scheduling technician time (90–100%) eliminates gaps between tasks.
Feedback and reporting, supported by CMMS systems, ensure continual improvement.
Barriers such as lack of time, fear of losing control, or lack of skills were also addressed and solutions shared.
2. Spare Parts Management
Spares are a significant but often mismanaged cost centre. The session highlighted that:
Only 5% of MRO items are frequently used.
20–30% of annual spend can be tied up in obsolete or excess stock.
Poor access to materials can add 10–25% in extra labour costs.
Delegates explored how to implement better cataloguing, remove duplicates, clean up data and adopt more proactive inventory policies, all of which support availability, reduce cost and improve uptime.
Real Feedback: The Exercise
Participants were asked to share their insights through a short exercise. Here’s a snapshot of what emerged:
What impacts your maintenance costs the most?
Equipment availability and emergency repairs
Ineffective stockholding and overstocking
Poor design practices and estimation methods
A hidden cultural issue – loyalty masking underlying problems
What would you improve to cut costs?
Shift to preventative maintenance
Investment in skills and retention
Strategic asset management plans
Stock optimisation and loosening of spare parts sourcing restrictions
Have budgets increased or decreased this year?
Most reported increased budgets, with rising costs in parts and services.
Some noted steady spend but redirected towards Capex and external contracts.
A Look at What’s Working
Case studies shared during the workshop showed clear results:
A chemical manufacturer reduced maintenance costs by £250k and spares by 20%.
A food producer developed a multi-skilled workforce, achieving significant reductions in downtime and enhancing asset reliability.
These stories demonstrated that a proactive, data-driven approach, supported by training and cultural change, yields measurable results.
A Few Words From Paul
"It was great to deliver a presentation on strategies to reduce maintenance costs, addressing an audience composed of professionals from a range of industries. The focus of the session was on two key areas: effective planning and scheduling and strategic spare parts management, both of which can significantly impact overall maintenance expenditures.
The presentation outlined how structured maintenance planning can reduce downtime, optimise workforce efficiency and minimise reactive work. We also explored the benefits of improved spare parts management, including inventory control, cost avoidance and reduced lead times.
The session was well-received, with positive feedback from several attendees who appreciated the practical insights and relevance of the topics discussed. The audience was engaged and there was active participation during the Q&A portion, which led to a valuable exchange of ideas across different sectors."
What’s Next? Join Us Again
Following the success of the Reading session, MCP is pleased to announce:
A Free Online Webinar later this year to explore maintenance cost reduction strategies.
A Mini-Roadshow across the UK, bringing these discussions to more regions and industries.
Details will be released shortly via our website and social media – we look forward to welcoming you!
If you would like to speak to one of our consultants about your maintenance challenges, please don’t hesitate to get in touch.