Activation of unused opportunities
This prestigious global chemical producer was doing a lot right,
well-conceived, efficient production processes with a strong focus
on customer satisfaction, integrated maintenance strategies and well
planned and executed turnarounds. However, changing market
conditions and an increase in demand were putting immense pressure
on its production capabilities. Although this site had been
operating for many decades, and the personnel there were skilled and
motivated, equipment failures and production losses were still
The maintenance of equipment was heavily dependent on gut feel instead of data-driven insight. So much so, that the failure of a part worth just $5,000 had cost the company a loss of $1.5 - $2 million. T.A. Cook developed a strategy focusing on reliability improvement. Here are some of the key achievements we accomplished with the project so far:
A lack of equipment and machinery reliability was a core issue that
had to be tackled as a matter of urgency. Using data from multiple
sources including sensors (IoT) and CMMS (SAP PM), as well as
technical feedback from operators, technicians, reliability
engineers and the asset manager, T.A. Cook was able to define
equipment strategies. These targeted Cook’s experienced engineers
and consultants worked on site for 12 months, aligning all staff on
the high impact failure modes and linked them journey they needed to
By focusing on Root Cause Analysis (RCA) and Failure Mode and Effect Analysis (FMEA), we were able to ascertain the causes go on. The critical areas of the biggest losses due to lack of availability, throughput or poor quality. Our specialists facilitated workshops to impart leading industry solutions on inspection and maintenance, and trained transformation were: reliability engineers in new methods. Throughout improvement of all the entire journey, top-level machinery on-site, workstream efficiency and streamlined turnaround / shutdown outages – all supported by a thorough change management was involved, along with a two-year, ongoing sustainability schedule for the improvements. strategy (from technician to director level).
Our experts helped realize $1.7 million savings in reduced equipment failures through improvement initiatives. It’s predicted that the business will save $6.3 million in lost opportunity over the next three years, thanks to our transformational recommendations. Above all, production at its main North American site increased and the long-term reliability of equipment improved.
“Corporate amnesia – when experienced technicians retire or move on – leaves a gap where a minor component can bring down a massive system, ending up with several millions dollars-worth of loss."