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
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)
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.
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.