Downstream energy
Downstream Energy Transformation and Operational Excellence
Operational assessment, Lean maintenance and work management improvement across multiple business units of a large integrated energy company.
- $22M+
- Recurring annual savings
- 23%
- More maintenance work completed
- 32%
- Reduction in contractor headcount
The situation
A large integrated energy company faced rising operating costs, ineffective maintenance planning and scheduling, contractor inefficiencies, inconsistent performance across business units, and limited visibility into improvement opportunities.
The challenge
Leadership needed a structured transformation approach to improve operational performance, increase maintenance productivity, strengthen accountability, optimize contractor utilization and deliver sustainable results.
The ISI approach
ISI Consulting Group partnered with executive and operational leadership to conduct a comprehensive operational assessment and establish an enterprise transformation roadmap.
Implementation
The work applied Lean operations, Lean maintenance, work management improvement, process mapping, value stream mapping, Kaizen facilitation, visual management, performance management, governance, organizational alignment and continuous improvement methods.
Leadership workshops, transformation planning sessions, process redesign workshops and Lean improvement events aligned stakeholders and accelerated implementation. ISI also strengthened leadership routines, performance reporting, implementation governance and execution disciplines.
Results
- Delivered more than $22 million in recurring annual cost savings
- Improved maintenance planning and scheduling, increasing completed work by 23%
- Reduced contractor headcount by 32% through improved contractor utilization
- Increased contractor wrench-time productivity
- Improved cooperation between Operations and Maintenance
- Standardized critical work management and operational processes
- Strengthened accountability through performance metrics, governance and leadership routines
- Established a sustainable continuous improvement framework
Key services applied
- Enterprise Transformation
- Performance-Based Implementation
- Operational Excellence
- Lean Operations
- Lean Maintenance
- Maintenance and Reliability
- Contractor Optimization
- Rapid Assessment
- Value Stream Mapping
- Kaizen Facilitation
- Workshop Facilitation
- PMO Leadership
- Performance Management
- Change Management
- Benefits Realization
Measured change
What moved
Maintenance work completed
23% higher
Contractor headcount
32% lower
Recurring annual cost
$22M+ removed
Figures as published for this engagement.
Rapid Assessment
Two to three days to find where the value is
A focused review of a site, a function or a single operational problem. Leadership receives a fact-based view of the performance gap, the likely value, the immediate priorities and the right next step.