Client Success in Operations:Refinery Turnarounds
The Challenge: Major Energy Firm
A leading Energy Producer's refinery turnarounds cost were rising rapidly. Work scope steadily expanded even as Contractor productivity declined.
Rapid Solution
Our maintenance, operations and contractor data analysis focused on
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Maintenance contractor productivity
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Warranties, Rework and Impact
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Total life cycle costs
Our Analysis revealed a "Fix only if broken" mindset to maximize daily production. Costs escalated from long lead items and delayed repairs. Poor planning led to site congestion reducing contractor productivity. These contributed to declining reliability reducing total production.
Our analysis identified the most productive and reliable contractors. The Energy Producer implemented
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Live Contractor Quality Score Card
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Planned repairs to non peak periods reducing congestion
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Optimized its long lead items ordering including spares
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Life cycle management for capital assets including sub assemblies
Result
The Energy Producer saved 12% of its annual budget and implemented category management for life cycle cost management. Overall plant reliability also started increasing driving higher total production.