Reduced Tank Outage Durations: Saved Over $3 Million
Increased Front-Line Productivity: One Additional Productive Hour Daily
Improved Cost Forecasting: +/- 5% Plan vs Actual
Tank Excellence Success Story
A large super-national operator engaged RLG at its UK refinery to improve tank maintenance, achieving significant reductions in tank outage time and cost predictability.
Energy
Maintenance & Reliability
Europe
“RLG have been game changers: helping us achieve in only a few months what we have not managed to do in years.”
— Tank Maintenance Lead
Context/Challenge
A large super-national operator’s UK refinery partnered with RLG to transform its tank maintenance processes. The key objectives were to reduce tank outage time, implement a stage-gate planning process (SGPP), optimize a 30-year tank plan, and enhance execution visibility and accountability across the business.
Approach
- Improved Planning: Conducted a comprehensive schedule quality review (SQR) program to establish baselines and identify gaps, enhancing execution and scheduling efficiency.
- Collaborative Workshops: Held workshops with key teams to improve alignment and highlight productivity improvement areas.
- Leadership Coaching: Implemented weekly coaching sessions to increase visibility into execution status and foster a culture of continuous improvement.
- Predictive Execution: Enabled predictive scheduling among contractors, effectively monitoring planned versus actual outcomes and harmonizing daily work plans.
- Adaptability: Embedded a meeting Operating Rhythm™ across all business levels, providing key leaders with necessary data for timely decisions.
- Sustainability: Ensured the client’s ability to autonomously use RLG tools for informed decision-making, ensuring long-term success.
Result
- Reduced Tank Outage Durations: Saved over $3 million.
- Increased Front-Line Productivity: Removing first-start delays resulted in one additional productive hour per person per day.
- Improved Cost Predictability: Enhanced maintenance and CAPEX cost forecasting over the next five years (+/- 5% plan vs actual).
- Long-Term Planning: Established a 30-year tank plan aligned to tank RBI intervals and production planning.
- Operational Stability: Achieved a consistent meeting Operating Rhythm™ that engaged front-line staff and contractors with refinery leadership.
- Cross-Refinery Engagement: Shared improvements across all the client’s refineries.
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