Operational & Maintenance Excellence at a tank storage company
Our client needed to invest in terminal expansion and renewal to remain competitive. To do that, costs had to be reduced and sales had to increase. The organization (operations, maintenance, CS, Sales) was mostly reactive. Both internally and externally (to the customer) in fire mode. Opposition was more common than cooperation, pointing at each other when something went wrong was normal. Preventing problems was out of the question.
Perform analysis of current OpEx and MainEx maturity. Analysis of current performance in terms of Delivery Reliability, Quality, Hands on Tool Time and Cost. Deepening on the root causes of the current performance and maturity. On this basis, together with the MT, we gave substance to Operational Excellence & Maintenance Excellence and started five projects:
- Integral Performance Management
- Integral Planning
- Multi skilling
- Work preparation and planning (MainEx)
- Supervision and Hands On Tool Time (MainEx).
The first 3 projects lead to integral cooperation between Maintenance, Operations and Commerce. The last 2 are mainly aimed at preventing waiting hours and increasing efficiency. At the same time, ambassadors (from all teams) have been trained to become Lean Greenbelts. They partly facilitate these projects and will initiate and facilitate continuous improvement in and from the teams. This together with the structures we put in place with the projects are the backbone of continuous improvement and the pursuit of Operational Excellence.
Learn more about Integral Planning and Integral Performance Management:
What is Integrated Planning?
What is Integrated Performance Management?
- Growth of the organization's OPEX maturity from level 1 (reactive) to (goal 2019) level 3 (structured)
- Continuous improvement behavior
- Improved planning reliability from 25% to 75%
- NPS growth of 35 points
- Operating cost reduction of 14% due to improved efficiency, hiring reduction and cost control within maintenance
The bottom-line result of the efficiency improvement is then 1.5 million Euros per year.
The ChallengeDuring a regular government audit, our client received an anomaly. It turned out...