Profit Improvement Program

Combining the deep industry experience of our consultants, our best practices and leading-edge technology, the Profit Improvement Program® methodology is a proven approach to unlocking sustainable, improved plant and bottom-line performance.

PIP overview diagram

Site-wide Facility Optimization

For over 40 years, the Profit Improvement Program (PIP) methodology has been KBC’s flagship process optimization solution with a focus on Non-Investment Quick Wins for an immediate return on investment. KBC has implemented over 150 profit improvement programs worldwide with an extensive client list including NOCs, IOCs, Independents and new owners. The results are achieved through:

  • Deploying a multi-disciplined team of subject matter experts with deep industry experience bringing an independent fresh view and objectivity
  • Applying KBC’s unique technology suite facilitating high-fidelity estimates of the improvement potential
  • Following a proven structured, rigorous methodology
  • Utilizing our change management expertise to facilitate, implement and sustain the changes in parallel with increasing commercial awareness, delivering best practices, and creating a culture of continuous improvement within our client’s organization

Profit Improvement Program Methodology Value Proposition

Our comprehensive approach can span the breadth of your business to identify and evaluate key sources of additional value.

  • Yield Improvement (from plant to site-wide and multi-site)
  • Energy and emission reduction
  • Supply chain optimization
  • Reliability, availability, and maintenance, including turnaround optimization
  • Human performance improvement
  • Major investment planning and feasibility studies

Our methodology doesn’t stop at evaluation. We work with our clients to implement the changes and realize the benefits in the bottom line. The Profit Improvement Program is typically cash flow positive in under a year, and implemented benefits via quick wins and minor investments are 5-10 times program costs.

Throughout the engagement, we work with our clients to improve work processes, deliver technology and build capability to ensure that the benefits of the program are sustained.

What Are the Benefits of a Profit Improvement Program?

Gross Margin Improvement (40%-80%)

The biggest benefits are in the hard-to-measure molecular management, constraint management and supply chain feeds/ product yield optimization areas. This is, by far, the most important and biggest areas for maximizing return on capital and shareholder return.

Cost Reduction (5%-10%)

This focuses on the reduction in energy costs and maintenance costs with energy reduction being the main driver. Even though the benefits are smaller, the benefits are easier to measure. The energy reduction dovetails into KBC’s Energy Transition Solution for decarbonization.

Find out more

Capacity Utilization (5%-40%)

This can be a major driver for profit maximization depending on the gap for asset utilization from best possible and turnaround cost, frequency and duration. This part of the program focuses on Defect Elimination and Turnaround Optimization.

Find out more

Human Performance (Sustainment)

No Profit Improvement Program can succeed without sustaining the profits from the implemented opportunities and a continuous improvement program. This focuses on building the organization’s human capability and the tool-set at their disposal. The tool-set includes digitalized technology, work processes and best practice operating procedures.

Find out more

Essential Pillars for a Successful Profit Improvement Program

Subject Matter Experts
Sustainment & Continuous Improvement
woman talking with colleague sitting at desk

KBC has a multi-disciplined team of experts spanning across process, operations, maintenance, utilities, automation and operational planning that are seasoned users of the supporting technologies and execution methodology. With their deep expertise, they bring a fresh view to identifying new areas to unlock value.

Our experts


KBC's flagship simulation tools, Petro-SIM® and Visual MESA® powered by our subject matter experts' hands-on industry knowledge and practical experience delivers an unparalleled assessment of current performance and future potential taking into account unit & market constraints and the non-linearities in unit operations.

4DS flow diagram

KBC has a clear proven methodology, developed over many years to ensure a successful and sustainable outcome which can be tailored to the scope and timeline required.

Sustain performance diagram

To ensure the benefits of the program are maintained, KBC works with our clients to ensure that a continuous improvement culture is in place supported by improved work processes and technology.

Find out about Digital Twin

engineers at chemical industry plant

Profit Improvement Program Delivers $280 MM of Benefits

KBC implemented a multi-year Profit Improvement Program to bring about a STEP change in operational performance with a focus on improving margins, reliability, and safety using KBC’s Best Practices. This was followed by a sustainment program supported by KBC’s Human Performance Improvement Offering and Technology. The results included implemented benefits of > 200 MM$/yr and cumulative benefits of ~ 280 MM$.  The sustained benefits were achieved via an organizationally aligned, trained capable workforce with a full technology tool-set and detailed multi-level 15 Work Processes and >2000 vetted Operating Procedures.

Sanjay Bhargava  - Profile Picture

Sanjay Bhargava

Principal Consultant

Meet our expert in profit improvement

"Maximizing profitability will require maximizing asset utilization, molecular management, constraint management, cost containment, and safe/reliable operation. The margins will continue to be volatile and the survival of the refiners will depend on making it through periods of low margins. There will be fewer refineries in the world but the remaining few will reap the benefits from their investments with high operating margins. Profit Improvement Programs (internally and externally) will be the need for the future.  Converting these programs into a continuous improvement program will be the key to surviving in the future."

More on this expert