Asset Productivity Customer Success
A global corporation with two large-scale grain export facilities in North America unloads river barges and trains with grain and then redistributes into the worldwide commodities market on container ships. Both export sites, each consisting of roughly 150 employees, transfer grain consisting mostly of corn, soybeans and wheat.
A goal for most automotive manufacturing operations is to increase speed and efficiency while keeping costs as close to the floor as possible. However, for one of the world’s leading truck manufacturers, this group didn’t just want to improve efficiency, they wanted to be recognized as a world-class leader in this category.
A large uranium mill, one of the industry’s leading producers, wanted to implement operational reliability best practices to maintain current capability and prepare for a future increase in production. Safety, employee engagement, efficiency, and increased production were the business objectives. After identifying potential for improvement in the mill’s maintenance processes and operational practices, management achieved measureable improvements, and reduced reactivity over several years. With the improvements in place, the mill now wanted to position itself to meet future business needs.
A major confection manufacturing operation in Georgia noticed an upward trend in Maintenance, Repair and Operations (MRO) costs which was negatively impacting the bottom line. Conservative estimates revealed that established processes had cost the company millions of dollars via redundant ordering and storing of non-critical parts. The plant reached out to Life Cycle Engineering for a complete MRO turnaround.
One of the largest consumer-operated, regional, joint-power supply ventures in the United States was operating in a constant state of reactivity. Coal power plants are under immense pressure to improve operational performance due to increasing regulations, rising costs, and continual loss of talented employees due to retirement. After a plant-wide gap analysis was conducted, the leadership team realized current reactive practices would not support continued sustainability and future business goals. The leadership team partnered with LCE to provide reliability and asset management expertise to improve performance.
A metallurgical coke producer, co-located with a large steel production facility in the middle of Detroit, Michigan, was struggling with reactive maintenance practices which were negatively impacting financial results for the company and creating a difficult work environment for its personnel. The site partnered with Life Cycle Engineering to establish an efficient, high-performance plant where employee quality of life was high and financial results stable.
A large alumina refinery site in the southwest United States was struggling with an aging plant and poor capital support for improvement of its installed equipment. The plant partnered with Life Cycle Engineering and embarked on a reliability journey to increase production, decrease the amount of reactive work and improve safety and quality of life for employees.
A very unique, large-scale coal gasification facility in the United States that manufactures synthetic natural gas and numerous chemical commodity products was struggling to improve its high-stress, reactive workplace. The team decided to partner with Life Cycle Engineering to improve performance through a proactive approach rooted in reliability best practices and strategic asset management.
AltaSteel is a scrap-based mini-mill operation based in Edmonton, Alberta, Canada. The plant has both melting and casting facilities and a production capability of over 315,000 tons of steel billet annually. AltaSteel makes a variety of round, flat, and square bar shapes for use by downstream remanufactures in the mining, oil and gas, automotive, construction, agriculture, and OEM industries.
Swagelok identified Reliability Excellence as a strategic improvement initiative and partnered with LCE to reduce downtime and improve OEE. Read how reliability engineering played an important role in their results.