The MCP Cost Savings Roadmap
A structured approach to sustainable maintenance cost reduction
Developed by MCP’s CEO, Peter Gagg and consulting team, this roadmap shows how organisations reduce maintenance and production costs without compromising asset performance, reliability or long-term value.
One roadmap.
Many steps.
Developed from over 50 years of experience working with manufacturing organisations, the MCP Cost Savings Roadmap sets out a structured, disciplined approach to delivering measurable and sustainable cost reductions through better maintenance and asset management decisions.
The roadmap shows how organisations systematically achieve:
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Lower maintenance costs
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Reduced capital expenditure
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Improved asset utilisation and OEE
The focus is on addressing the root causes of cost rather than reducing individual cost lines in isolation.
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Sustainable, repeatable savings rather than one-off cuts
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Roadmaps | Cost Saving
Get access to our interactive Cost Saving Roadmap and find out where you are.
The access includes:
Cost Saving Roadmap
Maintenance Improvement Roadmap
Operator Asset Care Roadmap (OAC)
Reliability Programme Roadmap
Spare Parts Management Roadmap
Maintenance Technical Strategy Roadmap
What we can support
Common cost saving challenges we see
Many cost reduction programmes fail to deliver lasting results because actions are taken in isolation rather than following the big picture structure.
Typical challenges include:
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Cost reduction actions taken in isolation rather than as a system
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Poor asset condition driving reactive spend and early capital replacement
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Maintenance strategies misaligned with asset criticality and life plans
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Excessive spares and procurement costs caused by weak governance
Low equipment reliability increasing hidden production and quality losses
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Short-term budget cuts creating long-term operational and financial risk
What’s inluded
How the roadmaps fit together
The main roadmap is made up of interconnected specialist roadmaps. Each can be addressed independently, but delivers greatest value when aligned as part of a single improvement programme.
Maintenance Improvement Roadmap
Provides the overall structure, linking governance, processes, asset decisions, and performance management.
Operator Asset Care (OAC) Roadmap
Defines how operators and maintenance teams work together to protect assets and improve day-to-day performance.
Reliability Programme Roadmap
Focuses on asset criticality, failure analysis, maintenance strategies, and long-term reliability planning.
Spare Parts Management Roadmap
Addresses inventory control, critical spares, obsolescence, stock policies, and lifecycle management.
Maintenance Technical Strategy Roadmap
Provides a structured approach to defining maintenance tasks, frequencies, aligned to objectives.
FAQs
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Sustainable maintenance cost reduction comes from improving asset condition, maintenance strategies and reliability practices, rather than cutting budgets or headcount. A structured, sequenced approach ensures savings are delivered without compromising safety or performance.
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Long-term savings are achieved by addressing the root causes of cost, including asset life planning, maintenance strategy alignment, spares management and operator asset care. Isolated initiatives rarely deliver lasting results.
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Many programmes fail because they focus on individual cost lines instead of the systems and decisions that drive them. Without the right sequencing, short-term savings often lead to higher costs and risk later.
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Effective asset management improves decision-making around maintenance, capital investment and risk. This leads to better asset utilisation, lower lifecycle costs and more predictable financial outcomes.
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Successful cost reduction requires alignment between senior leadership, engineering, maintenance and operations. Clear ownership and a structured framework are essential to deliver sustainable financial results.