Client Results
| Success Stories | ||
| Butane Sphere | ||
| at British Petroleum Refinery - Lima, OH | ||
| In just a few months, this team eliminated over $1.5 million annually in operational losses with only a $5,000 investment. | ||
| Turbine Generator | ||
| at Eastman Chemical - Kingsport, TN | ||
| Through a determination not to tolerate defects, this team determined the root cause of recurring turbine generator failures, saving in excess of $500,000 per year and over 128 manhours per generator per year. | ||
| The Centrifuge Team | ||
| at Eli Lilly - Lafayette, IN | ||
| By eliminating the defects in their centrifuge equipment, this team reduced their maintenance expenses by $150,000 annually and the additional up time has added production throughput and $5 million to their bottom line. | ||
| Improving the Odds in the Storeroom | ||
| at Alyeska Pipeline - Valdez, AK | ||
| By identifying and eliminating defects in their metering valves, this Action Team reduced downtime on actuators from 6 weeks to a maximum of 2 days. | ||
| Booster Pump Running in Error | ||
| Learn how this action team was able to save $10,000/yr. in energy costs as well as reduce the amount of maintenance work on a booster pump. | ||
| Compressor Bug | ||
| at Southern Natural Gas - Birmingham, AL | ||
| This action team realized a savings of $5,400 by eliminating a recurring compressor problem. | ||
| Overcoming System Defects | ||
| at Diesel Technology Company - Grand Rapids, MI | ||
| Learn how this action team tackled a defect in process & information, and achieved greater utilization of their Computerized Maintenance Management System CMMS). | ||
| Improving Titanium Dioxide Production | ||
| at ICI Manufacturing Technology - UK | ||
| Learn how this action team saved $872,000 by analyzing their concentrator reliability. | ||
| Field Charge Pumps | ||
| at Gulf Coast Refinery | ||
| By developing a contingency plan in the event of Feed Tank failure, this action team not only increased crude capacity, it also saved a potential penalty of $2 MM for a 5-day downtime. | ||
| Zero Delay | ||
| at BP-UK, Wytch Farms | ||
| This action team addressed Disinvestment & Reinvestment at their well sites and achieved an estimated savings of £150k/year. | ||
| Improved Spent Caustic | ||
| at Mobil Refinery - Beaumont, TX | ||
| Learn how this Action Team improved the bottom line between $600,000 to $750,000 per year by making minor re-design changes in their current Spent Caustic System. | ||
| Coker Backend Air Flow Resolved | ||
| at Clark Refinery - Port Arthur, TX | ||
| By removing "bad actors" from the air supply system, this Action Team solved a problem that was responsible for $73,600 lost margin in 1998. | ||
| Overheated Bearings Cause Compressor Failures | ||
| At Phillips Petroleum Corp., - Borger, TX | ||
| This Action Team determined the root cause of compressor failures and reduced the cost to maintain compressors by over $60,000/yr. and eliminated rental fee costs of over $100,000/yr. | ||
| Eliminating Purged Gas | ||
| At PCS Nitrogen - Trinidad West Indies | ||
| By identifying defects in their absorber feed pumps, learn how this Action Team eliminated $10,000/episode of purged gas. | ||
| FCC Unit Blowers Respond to Proactivity | ||
| At Premor Refining -Port Arthur, TX | ||
| By learning the value of "proactivity" this team eliminated on-going coupling changes at a cost of $40,000/coupling and saved over $285,000/yr in lost productivity and maintenance cost. | ||
| Our Clients Abitibi-Price A-Carb Aera Energy LLC Agrium, Inc. Alcan Alcoa Alyeska Pipeline American National Can Corp. Amoco Anglo Coal Arco Atofina Chemicals Bakkavor Foods Baton Rouge Community College Bermuda Electric Company BG Group BHP Steel (Australia) BP Chemicals BP Exploration and Production BP Solar International, Inc. Cabot Corporation Celanese Chevron Chemicals Chevron Phillips Chemical Co. CHS, Inc. Cimsa Clark Refining Coastal Eagle Point Colonial Pipeline Condea Vista ConocoPhillips CSR Sugar Dept. of National Intelligence Diesel Technology Dofasco Dow Corning Inc. DuPont Eastman Chemical Co. Eastman Kodak Elf Atochem Eli Lilly Entergy EPRI Ergon Exxon Coal & Mineral ExxonMobil Falconbridge Limited Firmenich Frontier Refining Georgia Gulf Corp. Goldcorp Mexico GPM Gas Corporation Grimaldi Tire Honda America Honeywell, Inc. Imperial Oil Inland Steel Iron Ore Co. of Canada Kimberly Clark Koch Petroleum Group Luzenac North America Lyondell-Citgo MA Hanna Co. Marathon Oil MeadWestvaco Michelin Millennium MIT Monsanto Monterey Coal Co. Motiva Enterprises, LLC Netherlands Refining Co. NiSource Nova Chemicals(Canada) Ltd. PCS Peabody Energy PEMEX Phillips 66 PPG Industries Premcor Rio Tinto Rohm & Haas Santos SASOL Synfuels Saudi Paper Company Schlumberger Technology Corp Searle SembCorp Shell E & P Shell Refining Southern Natural Gas Star Enterprises Sunoco Super Octanos Texaco Uncle Toby's (Australia) Valero VICO Indonesia Washington Group International Washington Penn Plastic Co., Inc. Western Mining Westlake Petrochemicals Weyerhaeuser Whirlpool |
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Reliability Goals
| We've been helping companies around the world achieve their reliability goals since 1993. We can help you. Let's Discuss How > |
Testimonials
"After playing the game myself, I saw this as a powerful tool to help change the way we think and act about our business."
Brian Johnson,
Alyeska Pipeline Service Co.
Brian Johnson,
Alyeska Pipeline Service Co.
"An Action Team of operators, mechanics and engineers found the root cause of our centrifuge problems, saving $150,000... and delivering $5MM additional throughput."
GayEllen Stulp, Eli Lily
GayEllen Stulp, Eli Lily
"Our Action Teams found and eliminated over 100 defects. The savings in our area exceeded $2 Million"
Micky Logan,
Eastman Chemical
Micky Logan,
Eastman Chemical
"The game shows that the interconnection of the functions has a bearing on how we do our maintenance.... Seeing this has changed my whole approach."
Jerry Leach,
Maintenance Planner
Jerry Leach,
Maintenance Planner
"The key thing that some of us woke up to was the idea of defects...the fact that they impact everything we do."
Tommy Fagan,
Weyerhaeuser
Tommy Fagan,
Weyerhaeuser
"The Manufacturing Game® played a major role in improving throughput by 21% without spending any significant capital."
Kirk Wolfinger,
Whirlpool
Kirk Wolfinger,
Whirlpool
"A cross functional action team modified a bracket magazine, which was shutting down the line. Their efforts produced an annual savings of $45,000."
Winston Lakshman,
PCS Trinidad
Winston Lakshman,
PCS Trinidad
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Featured Case Study
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Butane Sphere BP Refinery—Lima, OH In just a few months, this team eliminated over $1.5 million annually in operational losses with only a $5,000 investment. Read More > |
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