Life Cycle Engineering Success Stories

  • Grain Export Facilities Improve Reliability

    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.

  • Global Chemical Leader Uses Risk-Based Asset Management to Improve Maintenance and Reliability Performance

    A worldwide leader in global science recognized that their maintenance and reliability programs were performing significantly below world-class standards. To understand where the issues were occurring, the company conducted a maintenance and reliability assessment. The findings highlighted the four areas within the business that showed gaps in production efficiency: equipment and spare parts, data, workforce skills and capabilities, and their asset management system

  • Achieving Reliability Excellence through Customized Training: Bristol-Myers Squibb’s Journey

    Bristol-Myers Squibb (B-MS) is on a four-year Reliability Excellence® journey that requires changes in business processes, systems, tools, skills, and culture. B-MS began by engaging leaders in supporting and promoting reliability best practices. They also sought to build competency in the application of standard processes and best practices in reliability. This was a multi-site initiative that required buy-in training for employees from site leaders to technicians across 12 plants located in the United States, Mexico, Puerto Rico, Italy and Ireland.

  • World Leader in Chemical Treatment Improves Production Unit Performance with Reliability Engineering

    One of the world’s leading chemical treatment companies, specializing in industrial applications, recently installed a new production unit within their chemical plant. The unit was designed to propel the supplier into their market as the low-cost leader.

  • Power Cooperative Utilizes Training, Coaching and Follow-through Tool to Enhance Management Skills for Supervisors

    In late 2012, a power cooperative had the advantage of an experienced workforce and the ability to be a low-cost power producer. They were also confronted with considerable risks such as increasing costs, new regulatory requirements, and the retirement of skilled personnel.

  • Truck Manufacturing with World-Class Operations

    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. 

  • Uranium Mill Sets the Pace with Reliability

    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.

  • Major Confection Manufacturer Partners with LCE to Reduce Inventory Costs by $1.5 Million

    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.

  • NAVSSES Upgrades Machinery Control System, Brings Navy One Step Closer to First All-Electric Warship

    USS Makin Island (LHD-8), a Wasp-class amphibious assault ship, is the first U.S. Navy surface ship to implement systems and electric motors for distribution and electric propulsion. The purpose of the electric drive system is to save fuel by acting as an alternative to the gas turbine engines during low-speed operations, where gas turbines are less fuel efficient. Life Cycle Engineering (LCE) helped tackle design challenges of the Machinery Control System (MCS) to maximize effectiveness in a complex machinery environment. LCE performed software testing, training and installation for a seamless upgrade.

  • Fortune 500 Pharmaceutical Company Partners with LCE to Improve OEE and Save Millions

    A biotechnology and pharmaceutical company was struggling to meet customer demands and keep costs down. The company’s products treat genetic diseases, multiple sclerosis, cardiovascular disease and other rare diseases. The pharmaceutical company had exceeded its budget by $2.1 million due to inefficiencies in manufacturing. The company partnered with Life Cycle Engineering (LCE) to target a critical manufacturing line with risk-based asset management services - an engineering-based approach to equipment failure remediation and elimination of loss due to habitual poor maintenance and operator care.

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