Life Cycle Engineering Success Stories
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.
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.
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.
A major international offshore drilling company involved in the completion of exploratory and developmental oil and gas wells was struggling with international regulatory compliance standards. Its offshore drilling equipment includes drillship drilling rigs, semisubmersible drilling rigs and jack-up drilling rigs. As the fleet continued to expand with the construction of three state-of-the-art, dynamically-positioned, dual derrick ultra-deep-water drill ships, it was critical to maintain safety of employees and the environment while protecting financial stability.
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.