Program Outline

Module 1: Fundamentals of Production Cost Management

• Cost concepts and classifications
• Direct vs. indirect costs
• Fixed and variable costs
• Cost behavior analysis
• Cost drivers in manufacturing
• Cost structure in industrial organizations

Module 2: Production Cost Analysis

• Raw material cost analysis
• Labor cost optimization
• Energy cost analysis
• Maintenance cost evaluation
• Inventory carrying costs
• Cost benchmarking
• Manufacturing cost modeling

Module 3: Lean Manufacturing for Cost Reduction

• Lean Manufacturing principles
• Value Stream Mapping (VSM)
• Waste identification (Eight Wastes)
• Kaizen Continuous Improvement
• 5S Workplace Organization
• Standard Work
• Visual Management

Module 4: Improving Production Efficiency

• Overall Equipment Effectiveness (OEE)
• Productivity improvement techniques
• Capacity utilization
• Bottleneck analysis
• Cycle time reduction
• Process optimization
• Production scheduling

Module 5: Energy and Utility Cost Optimization

• Industrial energy management
• Energy efficiency assessment
• Utility consumption monitoring
• Compressed air optimization
• Furnace efficiency improvement
• Waste heat recovery
• Renewable energy opportunities

Module 6: Maintenance Cost Optimization

• Preventive Maintenance (PM)
• Predictive Maintenance (PdM)
• Reliability-Centered Maintenance (RCM)
• Total Productive Maintenance (TPM)
• Spare parts optimization
• Downtime reduction
• Equipment life-cycle costing

Module 7: Quality Improvement and Cost of Quality

• Cost of Quality (COQ)
• Prevention costs
• Appraisal costs
• Internal failure costs
• External failure costs
• Six Sigma fundamentals
• Root Cause Analysis (RCA)

Module 8: Inventory and Supply Chain Cost Reduction

• Inventory optimization
• Economic Order Quantity (EOQ)
• ABC Analysis
• Just-In-Time (JIT)
• Supplier performance management
• Procurement cost reduction
• Logistics optimization

Module 9: Digital Technologies for Cost Optimization

• Industry 4.0 applications
• Artificial Intelligence in manufacturing
• Industrial Internet of Things (IIoT)
• Manufacturing Execution Systems (MES)
• Data analytics for cost reduction
• Predictive analytics
• Smart manufacturing

Module 10: Profitability Improvement Strategies

• Profitability analysis
• Contribution margin analysis
• Break-even analysis
• Product mix optimization
• Pricing strategies
• Cost-benefit analysis
• Financial performance improvement