Improving Crude Throughput by 25% via Lean Process Optimization
Client Context
- Major refinery experiencing crude processing constraints
- Faced crude processing constraints due to light naphtha accumulation
- Partnered with EFESO to enhance barge logistics and throughput in 3 days
Key Challenges
- Crude constraint caused by light naphtha accumulation due to export delays
- Unidentified root cause of bottleneck limiting crude and naphtha throughput
- Limited process visibility and inconsistent data collection
- Lack of standardization — no clear SOPs or defined role expectations
- Inefficient loading operations with bottlenecks and unbalanced workflows
Approach & Key Success Factors
- Achieved $6.5M annual margin gain through increased crude throughput.
- Reduced barge load time by 25%, eliminating waiting and transport delays.
- Streamlined operations by removing 20% of process steps for higher efficiency.
- Naphtha export delays created a bottleneck limiting crude throughput.
- Lack of visibility and standardization across the barge loading process.
Results
$6.5M
Annual margin gain through increased crude throughput
25%
Reduction in barge load time, cutting wait and transport delays
20%
Fewer process steps for simplified, more efficient operations