Case Studies

Working with asset intensive companies for over 20 years, we have partnered with many different industry sectors including refineries such as chemical, oil and gas, phamaceutical, or fast moving consumer goods industries such as food and beverage, packaging and paper mills, infrastructure and utility sectors and construction. Our consulting team has industry knowledge, best-practice and practical hands-on experience to help optimize your business. Read our featured case studies to find out how we added value to the projects of our clients.

Read more Maintenance Maintenance

Petrochemical Complex Realizes 72% Maintenance Productivity Improvement

Petrochemical Complex Realizes 72% Maintenance Productivity Improvement

T.A. Cook helped a large petrochemical complex improve their maintenance time-on-tools productivity by 72%. An assessment quantified the improvement potential and identified the improvements required. The complex optimized their maintenance work management process and T.A. Cook conducted training and coaching to enable front-line supervisors to proactively guide their crews to maximum productivity.

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€2.9 million potential savings in maintenance

€2.9 million potential savings in maintenance

Consulting partner T.A. Cook discovered potential maintenance optimization gains of €2.9 million for a specialty chemical company’s global maintenance operation. Employing new technologies, T.A. Cook came up with the means to compare the dispersed maintenance teams’ global performance.

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8h allocated to equipment inspection when it was just taking 2 ...

8h allocated to equipment inspection when it was just taking 2 ...

T.A. Cook partnered with a leading metallurgical company to transform the way their assets were maintained. Inefficiencies and waste had crept in across its five worldwide sites and it was running out of cash. T.A. Cook helped the client break the vicious cycle of corrective maintenance by dramatically reducing the need for expensive, unplanned machine repair work.

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Increase in operational output in an international chemical business

Increase in operational output in an international chemical business

Through optimization in production, maintenance and service the overall equipment effectiveness was to be increased by five percent. T.A. Cook coordinated and managed the project and all change activities.

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Fast delivery of worldwide best practices stopped metallurgical company to burn through money

Fast delivery of worldwide best practices stopped metallurgical company to burn through money

A world leader in metallurgy was facing challenges through competition, high costs for recources and internal inefficiencies. T.A. Cook stepped in and supported them with the global rollout of its maintenance and reliability approaches.

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European Port Operator Improves Asset  Utilization and Reduces Costs

European Port Operator Improves Asset Utilization and Reduces Costs

One of the world's largest port operators wanted to reduce procurement spending and administrative complexity across a number of containerized freight sites. The challenge was to minimize the time taken to turn ships around and the “cost per movement” while using unionized labor to run both automated and semi-automate loading and unloading systems.

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Maintenance backlog reduction in seven weeks at US chemical plant

Maintenance backlog reduction in seven weeks at US chemical plant

A US-based olefins and polypropylene manufacturer was having difficulties coping with its maintenance backlog and excessive overtime hours. The chemical company contacted T.A. Cook to conduct an analysis and implement a plan to improve maintenance efficiency.

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Oil & Gas company increases offshore inspection and maintenance efficiency

Oil & Gas company increases offshore inspection and maintenance efficiency

T.A. Cook partnered with a top tier Oil & Gas giant to increase its inspection and maintenance efficiency. Aim was to improve their maintenance work definition processes allowing offshore staff to execute work as planned when scheduled.

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Read more Reliability Reliability

Covid-19 inspires new remote working approach

Covid-19 inspires new remote working approach

In the midst of a collaborative reliability improvement project between T.A. Cook and a leading petrochemical facility, a global pandemic forced a change in typical working processes and means of communication. In response to intense new safety restrictions T.A. Cook facilitated remote workshops to keep the project moving forward toward timely completion.

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Sustainable impact on bottom line thanks to quick changes to equipment reliability

Sustainable impact on bottom line thanks to quick changes to equipment reliability

We partnered with a metallurgical company. The volatile reliability of its critical equipment across its five global sites was causing unplanned downtime. T.A. Cook developed a more proactive and lucrative approach to manufacturing with our localized world-wide best practices.

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$6 million reduction in lost opportunity predicted

$6 million reduction in lost opportunity predicted

A global chemical producer was facing changing market conditions and increased demand was putting pressur on its production capabilities. T.A. Cook’s experienced engineers and consultants worked on site for 12 months, aligning all staff on the journey they needed to go on.

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New operational strategies deliver fixed cost reduction at European paper mills

New operational strategies deliver fixed cost reduction at European paper mills

The leading producer of pulp and paper was based in Europe but also had an international presence. They were hoping to implement cost-cutting measures to be increasinglycompetitive. Having already carried out cost reductions after the financial crisis, the producer looked for additional ways tooptimize their fixed cost base.

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South American PVC plant optimize maintenance efficiency

South American PVC plant optimize maintenance efficiency

An international chemical company wanted to optimize their maintenance management processes at a South American PVC plant. Although the plant had an annual maintenance budget of approximately €13 million there were irregular patterns of expenditures, sloppy inventory management, and rising salary costs, which were higher than their European partners.

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Read more Shutdown, Turnarounds & Outages Shutdown, Turnarounds & Outages

Turnaround excellence is key to improving business performance

Turnaround excellence is key to improving business performance

A major downstream gas and refinery producer couldn’t achieve major performance improvements the business required. A TAR excellence transformation program put in place the standards that enhanced quality of TAR preparation and made execution more efficient, cost effective and safe across 6 sites.

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How managing risk reduced an STO by 4 days

How managing risk reduced an STO by 4 days

T.A Cook partnered with a North American refinery to better manage their STO risks and achieve their cost and duration targets. A risk management plan was developed, that prioritized project risks though the impact of STO schedule duration, cost and lost production revenue (LPR).

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Best - Practice TAR Planning Saves $CAN 1.2 million at Canadian Petrochemical Plant

Best - Practice TAR Planning Saves $CAN 1.2 million at Canadian Petrochemical Plant

A leading Canadian petrochemical producer was planning for an approaching turnaround (TA), but it was not being carried out according to initial forecasts. The site asked T.A. Cook to execute a one - week assessment to identify potential improvements for the event’s preparation and execution.

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Long Term Optimization Changes for STO Preparation and Execution

Long Term Optimization Changes for STO Preparation and Execution

At a large refinery, STO's exceeded schedules and budgets for eight consecutive years. Investment needs for another five years in the triple-digit millions required sustained cost reductions.

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TAR Execution Improvements Analysis Results in  23% Labor Savings at Scandinavian Refinery

TAR Execution Improvements Analysis Results in 23% Labor Savings at Scandinavian Refinery

A Norwegian refinery was interested in identifying potential preparation and execution improvements for their upcoming TAR. The site approached T.A. Cook to conduct a three-week analysis.

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Read more Capital Project Capital Project

Project Definition and Delivery  at an  International Chemical Company

Project Definition and Delivery at an International Chemical Company

A large chemical site finished a company restructuring project, which included creating new business units. After this phase of the venture was completed, they sought to move a step further and increase efficiency, build on core competencies and reduce their reliance on contractors.

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Proactive Intervention Gets US Refinery Project Back On Track

Proactive Intervention Gets US Refinery Project Back On Track

A diversified Fortune 100 company providing essential energy resources to businesses and consumers around the world was concerned about one of their North American refinery site’s project cost and schedule overrun.

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Read more Operations & Asset Management Operations & Asset Management

Increased competitiveness by following intelligent asset management strategies

Increased competitiveness by following intelligent asset management strategies

A streamlined, efficient asset management in the form of a sophisticated preventive maintenance strategy leads to cost reductions and to an increase in technical availability, reliability, and thus to an increase in competitiveness.

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Contractor Management: Multi-Site Analysis in Latin America

Contractor Management: Multi-Site Analysis in Latin America

Within an international expansion, a German special chemicals company acquired a South American company. Due diligence revealed areas in Contractor Management where significant cost reductions could be achieved. T.A. Cook was assigned to conduct an analysis as a basis for the planned optimization.

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Reducing changeover time by 50% at a cosmetics manufacturer

Reducing changeover time by 50% at a cosmetics manufacturer

The growth strategy of an international manufacturer with three European locations should be flanked by increasing the OEE and minimizing unproductive downtimes.

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Read more Change Management Change Management

Building Maintenance Excellence with a  Culture of Flexibility  in Belgium

Building Maintenance Excellence with a Culture of Flexibility in Belgium

A chemical site in Belgium wanted to assess their current needs and identify areas in which they could cut costs. T.A. Cook was asked to perform a full maintenance review to find this information. Following a three week analysis, a variety of improvement opportunities were revealed.

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Defining and delivering radical reorganization for securing site survival

Defining and delivering radical reorganization for securing site survival

A heavily-unionized petrochemical site in France suffering from under-investment and underperformance got two new investors, as a joint venture (JV). T.A. Cook was commissioned for an independent assessment of all optimization options at the site.

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Productivity Gains at Leading Private  Brewer in the UK

Productivity Gains at Leading Private Brewer in the UK

A leading private brewer in the UK was operating abottle-fillingcontract service for over fifty clients. An uptick in market share meantled toan increase variety of packaging materials, a larger amount of stock keeping units (SKUs)andmore complexity across the supply chain. In order to accept new customers, they needed to optimize for increased production capacity.

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Read more Manufacturing Manufacturing

Achieving Productivity Gains in the FMCG Sector

Achieving Productivity Gains in the FMCG Sector

An international FMCG (fast-moving consumer goods) company specializing in confectionery sought to standardize maintenance procedures across all their sites. The organization approached T.A. Cook to conduct an analysis and subsequent 12-month pilot project overall the firm’s German projection sites, the organization’s fastest-growing market.

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Maintenance Cost Reduction at Global Polypropylene Manufacturer

Maintenance Cost Reduction at Global Polypropylene Manufacturer

A global film and packaging manufacturer had trouble with ballooning maintenance costs. They hoped to reduce overall expenditure in the department by 20%. The site approached T.A. Cook to identify key areas of improvement to achieve lean maintenance.

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Read more Contractor Management Contractor Management

Improving Active Supervision at a Large European Petrochemical Site

Improving Active Supervision at a Large European Petrochemical Site

A European petrochemical site utilized contractors on their large site. The expense was higher than desired, which led the company to reach out to T.A. Cook to review site processes and make suggestions for third-party employee management.

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UK Railway Reorganizes Contractor Management

UK Railway Reorganizes Contractor Management

A large metro railway operator serving 200,000 people every day across six main depots was seeking new ways to improve upon old management and update. They had been using outdated processes dating back to its duration under state ownership.

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Read more Engineers Engineers

Engineering specialists achieve successful shutdown at leading chemical company

Engineering specialists achieve successful shutdown at leading chemical company

Due to a resource shortage in their existing team, a leading chemical company required on-site support to enable the successful execution of pending shutdowns for strategic key plants.

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Successful TAR project management in the German food industry

Successful TAR project management in the German food industry

A leading European market producer of raw corn starch and saccharification products for food, feed and paper in the chemical, pharmaceutical and technical industries was planning a turnaround (TAR). The previous TAR at the 600-employee site was behind schedule and exceeded the allotted budget by 100%. The manufacturer approached T.A. Cook Engineers to commission a new shutdown culture in five months.

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1 SAP for 8 refinaries

1 SAP for 8 refinaries

An international oil company implement a worldwide Global Manufacturing Template with the goal of creating synergies in relation to data processing and documentation for all systems. T.A. Cook structured the technical plans and data from the locations and entered them into a central SAP system for 8 refineries.

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