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Improving availability and reducing turnaround costs to increase production and profitability

KBC undertook an extensive assessment of a Japanese multi-site refiner’s Operation Management Systems which identified that on-stream & shutdown maintenance practices was resulting in a loss of availability due to short turnaround cycle length and long duration of Turnarounds. KBC applied our TOP™ methodology over three sites to improve stakeholder alignment, organizational change as well as challenge scope and conduct schedule optimization.

The challenge

Achieve world class performance in turnaround by reducing work scope, schedule and costs whilst also allowing increased availability and associated revenue.

Solution

KBC’s applied a thirteen month Turnaround Optimization Program, with structured reviews from TR-0 to TR-4 in head office and the three refineries

KBC provided awareness of modern turnaround practices and tools, with agreement on gaps and areas of improvement on the whole turnaround process leading to optimizing the work scope through rigorous work selection and risk based awareness training of employees.

The budget was minimized along with the schedule through monitoring and control strategies on contractor performance and allocation of resources.

KBC provided knowledge transfer for efficient execution of turnarounds throughout review process and streamlined shutdown and start-up procedures as well as the contractor on-boarding process.

The results

Implementation of the TOP program achieved a 10% - 15% reduction of turnaround work scope. Over $50 million benefits were gained through increased availability and shorter turnaround length with $11 million quick wins achieved during the initial phases of the study.

Our client says

‘’We are very happy with the work performed by KBC as this has enabled us to implement opportunities after thorough discussion and full agreement on the gaps identified in the existing turnaround strategy and methodology. KBC Subject Matter Experts are highly experienced in world class turnarounds and helped us in achieving quick wins of 11M USD by optimizing shutdown & start up procedures, turnaround scope and schedule. Additional long term improvement opportunity has been identified for future events with ongoing multi-million dollar annualized benefits. ‘’

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