Transforming Tank Farm Maintenance: Driving $10M Savings with Cultural and Structural Change
Client Context
Major refinery tank farm experiencing:
- Siloed teams
- Resistance to SAP changes
- New maintenance metrics
- Planning/reporting gaps
Key Challenges
- Inefficient inspection programs with significant repeat work and safety concerns
- Overall safety risks identified in multiple areas the refinery symptomatic of a larger cultural problem.
- General change management problems
- “We have always done it this way” mentality
- Middle management resistance to change
- Inability to accept partnership – preferred
Approach & Key Success Factors
The EFESO team worked with the local team to identify the root causes of the change management needs, as well as opportunities to reduce cost:
-
- Implemented maintenance “Rapid Improvement Teams” with “Loss Elimination” boot camps
- Restructured of the reliability & maintenance department to result in a fully integrated organization
- Performed critical analysis for tank farm equipment and supporting areas
- Established maintenance metrics to provide clear direction
- Weekly/monthly critical metrics and area dashboards created with weekly review with team during command center meetings
- Removed historical organizational silos
- Aggressively reviewed/challenged backlog
Results
98%
PM compliance achieved
90%
Overall schedule compliance
60%
Reduction in tank farm maintenance backlog
80%
P1 reduction
$10M
OPEX reduction