Energy and Transportation 2017-09-12T15:51:07+00:00

energy and transportation case studies

We’re solving tough problems for hundreds of Industry, Healthcare and Government clients.

Response Time Project – “No Fluid Detected” Wells

OIL EXPLORATION AND DRILLING COMPANY

The organization’s response time to “No Fluid Detected” wells was impacting production and overall profitability.

  • $2,500,000 in annualized ROI was created for the Oil Exploration and Drilling company
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Improving Aircraft Engine Disassembly

AIRLINE

Turnaround time (TAT) for engine repair and overhaul was taking a business on the average of 62 days. The critical-to-quality (CTQ) was 45 days. The customers had to compensate for the poor TAT by having more engines in inventory. 

  • Variation in the cleaning and inspection process was reduced by 57%
  • Overall engine repair and overhaul TAT was reduced 37%
  • Inventory reduction and labor productivity increases produced nearly $6 million in savings
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Water Treatment – Solids Reduction

WATER TREATMENT

A Water Treatment facility measured their total solids to be 7 times the specification and treatment costs to be $.14 per barrel. Improvements were required to reduce this cost and bring water quality within required specifications.

 

  • Project yielded $854,000 in annualized ROI (Return On Investment)
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Soft Water Usage in Oil Reclamation

OIL EXPLORATION AND DRILLING COMPANY

A major oil exploration and drilling company was experiencing problem with soft water usage by steam generators in their oil reclamation processes.

 

 ROI benefits:
  • $1,000,000 from chemical savings 
  • $18,900,000 from increased oil production
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Oil Content of Injection Water

OIL EXPLORATION AND DRILLING COMPANY

An oil exploration and drilling company needed to reduce the oil content of injection water and improve oil production.
 ROI benefits:
  • $800,000 in annualized ROI from the increase in oil production
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One Plant’s “Go Green” Project

SOUTH AMERICAN MANUFACTURING FACILITY

One Plant wanted to minimize power consumption while maximizing their resources.
  •  annual electric power use dropped by over 1 million kilowatt hours, resulting in savings of over $400,000 per year
  • water usage was reduced by over 75,000 liters per year, resulting in additional consumption and treatment savings
  • 400 employees arefully engaged and motivated to maintain these energy saving benefits
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Periodic Well Test Process

OIL AND GAS DRILLING COMPANY

Improve well test accuracy and overall capacity 

ROI results:

  • $400,000 in better well work decisions 
  • $100,000 in the value of extra test capacity
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Underutilization of Airport Kiosks

AIRLINES

 Increase the use of kiosks and decrease the need for check-in agents.

ROI results:

  • Call Air Academy Associates for the results from this case study! They are remarkable.
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Automotive Chemical Process Parts

CHEMICAL PROCESS- AUTOMOTIVE

Decrease cycle time and build a predictive model
  • the regression model produced was optimized to shorten the process cycle time by a factor of 2,resulting in a 100% improvement over the historical setting
  • the control phase Cpk had improved to 1.0 with a 0.26% defective rate representing an improvement nearing 2 full orders of magnitude from the baseline performance.  
  • project met all goals with estimated future savings of $100,000
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Automatic Well Test Process

OIL AND GAS DRILLING COMPANY

Improvements were needed to their automatic well test processes to increase test accuracy and productivity.
  • $500,000 in annualized ROI
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Crankshaft Production Failures

AUTOMOTIVE

Excessive crankshaft production failures
  • $100,000 in annualized ROI
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Drive Train Reliability – DFSS

AUTOMOTIVE

The drive train subsystem for this large-scale business product has a design target of 5,000 hours. The initial subsystem design, completed by an external motor supplier, was failing well short of this target.
  • yielded a 13X improvement in reliability 
  • a 10X cost reduction
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High Variability in Titration Measurement System

ALUMINA REFINERY

The refinery was experiencing high variability in their titration measurement system. Titration measurement is the quantitative chemical analysis that is used to determine the unknown concentration of chemicals. This was resulting in high variability in the process chemistry.
  • ROI benefits of $180,000
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