Success stories

Read our related asset integrity assurance consulting case study

KBC was tasked with implementing maintenance and reliability practices across global operations at a world leading chemical company. The objective of the project was to improve the company’s overall performance and competitive position.

The challenge

The customer operated across several geographic locations in North America, Europe and China. Preliminary assessments across these sites highlighted differing systems, cultures and human behaviors, leading to a range of processes, methodologies and levels of performance. The primary challenge of the project was thus to implement new and consistent practices across the company’s sites.


KBC’s approach was to take the best from existing company practices, incorporate them with the highest industry standards, and then roll-out these new practices across the customer sites to create a new corporate standard. New methodologies were implemented to either complement or replace existing ways of managing reliability and maintenance. These included:

  • Risk management, utilizing risk analysis to support efficient and effective decision making
  • Routine maintenance planning and scheduling, with enhanced use of CMMS
  • Asset policies, developing optimal asset care programs to cover operation, predictive and preventive maintenance
  • Defect elimination, covering the systematic analysis of problems to identify root causes and ensure no repeats
  • Performance management, to drive a culture of continuous improvement using targeted key performance indicators

The results

The identified benefits of the project across global operations exceeded €250 million per year in profit improvement. This was achieved through the increased utilization of assets and a reduction in maintenance costs of over €100 million.

Share this

Get in touch with us

Do you have a project you're interested in
working with us on?

You may also be interested in


Key steps for delivering autonomous operations

Feb 4, 2020

Achieving autonomous operations is all about empowering the plant to run, learn, adapt and thrive in tomorrow’s environment. Dynamic real-time optimization gives a fast automated response based on the actual changes in raw material properties, product demand, and operating conditions.

Read full article

KBC and OLI Systems announce predictive software solution to mitigate USD 65 billion/year corrosion and scaling problems across the oil and gas industry

Jun 3, 2020

Petro-SIM® and the OLI Alliance Engine digital twin mitigates operational risk, increases efficiency, and prevents revenue loss.

Read full article

The right decisions in abnormal situations

May 13, 2020

Sanjay Bhargava, Principal Consultant

Do you have an accurate representation of your plant to drive the right decisions in your organization at this critical time?

Read full article

Get the latest updates from KBC

Sign up to our newsletter to receive our latest innovations, viewpoints and be informed about any upcoming events.