Service
Operational Excellence
Data-driven improvement work that is implemented rather than recommended, and still running twelve months later.
The problem this answers
Operating costs are rising, maintenance is reactive, and the last improvement program did not hold.
Capabilities applied
- Cost reduction and opportunity sizing
- Productivity improvement
- Lean operations and Lean maintenance
- Work management, planning and scheduling
- Contractor utilization and wrench-time productivity
- Value stream mapping and Kaizen facilitation
- Visual and daily management routines
- Performance management and leadership routines
- Operational assessments
- Continuous improvement frameworks
How the engagement runs
Four steps, each with an owner and an output
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2 to 3 days
Assess
A focused review of one site, function or operational problem. Leadership receives findings, a preliminary benefit range and the immediate priorities.
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2 to 5 weeks
Baseline
Operational and financial baseline, process and value stream analysis, root cause validation, and a prioritized opportunity portfolio with a business case.
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By scope
Implement
Initiative mobilization, process redesign, Kaizen events, leadership routines and benefits tracking, delivered alongside the operating teams.
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Ongoing
Sustain
Performance reporting, accountability routines, training and knowledge transfer, then periodic audits to verify the gain held.
Already delivered
Outcomes recorded on engagements using this service
$22M+ recurring annual savings
Read the downstream energy engagement- More than $22 million in recurring annual cost savings in downstream energy
- 23% increase in completed maintenance work
- 32% reduction in contractor headcount through improved utilization
- More than $12.2 million in annualized savings in manufacturing
Client identities are withheld under confidentiality agreements. Results vary by engagement.
Engagements
Where this service was used
$22 million in recurring savings in downstream energy
Operational assessment, Lean maintenance and work management improvement across multiple business units of a large integrated energy company.
Read the engagement- $22M+ Recurring annual savings
- 23% More maintenance work completed
- 32% Reduction in contractor headcount
$12.2 million saved through reliability and Lean transformation
Planning and scheduling redesign, daily management routines and sustainment governance on the plant floor.
Read the engagement- $12.2M Annualized savings
- 33% Productivity improvement
- 1,338 to 879 Maintenance backlog reduced
Schedule quality improved by up to 50% across a pipeline network
Advanced planning and scheduling built on optimization, simulation and automated scenario evaluation for a major energy infrastructure organization.
Read the engagement- 33% to 50% Improvement in schedule quality
- 9% to 18% Lower projected power costs
- 11% to 25% Fewer operational shutdowns
Outcome-based solutions
Solutions delivered through this service
Manufacturing Performance Improvement
Higher throughput, productivity, reliability and schedule attainment.
ExploreSG&A Cost Optimization
A sustainable cost structure with clearer accountabilities and protected capabilities.
ExploreLNG and Midstream Performance Improvement
Improved asset reliability, contractor effectiveness, materials readiness and cost control.
ExploreRapid Assessment
Start with a Rapid Assessment
Two to three days on the operation, the function or the program in question. Leadership receives findings, a preliminary benefit range and the recommended next step.