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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 meeting 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. |