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Leveraging Expert Leadership & Lean Six Sigma For a 40% Reduction in Deferment of Oil Production

Situation

MetaExpert, Kip, was sought after by a  large Oil and Gas company that faced significant challenges in one of its offshore operations. The primary issues involved the reliability-centered maintenance and their utilization of SAP S/4 HANA software. The organization lacked expertise in optimizing maintenance plans and struggled with logistical constraints in acquiring and delivering parts to remote offshore platforms.

Actions

To address these challenges, MetaExpert Kip:

 

  • Collaborated with reliability engineers to refine reliability-centered maintenance practices.
  • Leveraged his knowledge of Lean Six Sigma methodologies to train the team on tools such as Failure Modes, Effects Analysis (FMEA), and DMAIC (Define, Measure, Analyze, Improve, Control).
  • Engaged with supervisors, team leads, mechanics, electricians, and operators, ensuring their involvement in the decision-making process. Through his guidance, the team gained a sense of ownership and responsibility for the maintenance process.

Results

  • Reduced unplanned breakdowns: Achieved a significant reduction in unplanned breakdowns, enhancing overall equipment reliability.
  • Lowered maintenance costs: Effectively reduced maintenance expenses, resulting in improved cost efficiency.
  • Improved safety: Emphasized safety measures and taught employees how to predict and prevent breakdowns, leading to a safer working environment.

 

Return on Investment

  • The Oil and Gas company saw a 40% reduction in deferment of oil production, resulting in substantial financial gains due to reduced downtime and increased productivity.

     

    Skills needed:

    • Troubleshooting and problem-solving
    • Expert communication and collaboration
    • Lean Six Sigma Expertise
    • Data-driven decision making
    • Data analysis

     

    Contract Length:

    The initial contract was for 1 year but was extended to a remarkable 11 years due to the positive outcomes and the client's satisfaction with the MetaExperts' performance.

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