Asset Productivity Customer Success

  • An Aluminum Cast House Throughput Study Identifies Strategies to Improve Output by 13%

    An aluminum producer needed to increase production capacity. It turned to Life Cycle Engineering (LCE) to help with a specific issue: identifying how the aluminum plant cast house could increase throughput to meet the increased demand for aluminum billets.

  • Even Small Wins Matter - Improving a Pulp-and-Paper Mill’s Sheet-Break Recovery Time

    As part of implementing Reliability Excellence in a large pulp-and-paper mill, Life Cycle Engineering, Inc. (LCE) assigned a Lean subject-matter expert to identify and eliminate production losses and aggressively investigate potential limiting factors that could be resolved quickly. These loss-elimination activities had two objectives. First, to begin the change process by getting the workforce involved in resolving problems that negatively affect the plant. Second, to generate immediate improvement in plant performance and profitability.

  • Calculating Total Cost of Ownership Requires Knowing the Cost of Materials

    A food manufacturer with several existing production lines spread across the U.S. wanted to determine the total cost of ownership before designing and building a new line for one of its plants. They had excellent analysis on raw materials, operating costs, and projected typical capital project spending for improvements. However, they did not have the same level of information to review maintenance material spend, an important component of total cost of ownership. Because they lacked the data, they asked Life Cycle Engineering (LCE) to evaluate and develop a 10-year maintenance material spend forecast based on their most recent production line in operation.

  • Drilling into the Data Helps a Steel Company Reduce Downtime and Improve OEE

    A steel producer was incurring significant unscheduled downtime due to equipment and processing issues. This was particularly problematic because the company was struggling to meet market demands.

  • How a Cheese Manufacturer is Meeting Growing Customer Demand

    A cheese manufacturer has engaged with Life Cycle Engineering to apply a time-tested Reliability Excellence® (Rx) approach to meet its objectives.

  • Solving Motor Issues Reduces Production Downtime for a Major Steel Company

    An integrated steel producer with major production operations in the United States and Central Europe was encountering various motor issues as well as critical equipment availability of required repair parts.

  • A Global Pharmaceutical Manufacturer Applies RBAM to Improve a Filling Line’s Reliability

    A diversified, global healthcare leader produces vaccines and other injectables in one of its U.S. locations. A focus on equipment availability and uptime was a priority due to market demands and patient needs. The manufacturing facility reached out to LCE for help with improving utilization of maintenance time and resources in their aseptic filling area.

  • Hot Strip Mill Regaining Former Status

    In 2017 a major steel company decided to focus on a significant reliability improvement initiative at several of their steelmaking operations. Improvement in reliability was needed in many of the operations. But none were more important than their hot strip mill, which needed to produce the lion’s share of the company’s products.

  • A Steel Mill Mitigates Impact of Shutdowns with an Operational Risk Assessment and Risk Register

    A steel production facility dating back to the early 20th century had not undergone major modernization since the late 1980s. Reliability and quality across the operation was suffering. A hot mill upgrade project was designed to change out major equipment, control systems, and services while maintaining scheduled production. Five outages, over 26 months, were planned to execute the activities that require a total hot mill shutdown.

  • Brownsville Public Utilities Board Implements Asset Management Best Practices

    The Brownsville Public Utilities Board (BPUB) was formally chartered by the city of Brownsville in 1960 to provide electrical, water and wastewater services to its customers in the southernmost part of Texas.

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