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.
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
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.
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.
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.
One Plant’s “Go Green” Project
SOUTH AMERICAN MANUFACTURING FACILITY
An oil exploration and drilling company needed to reduce the oil content of injection water and improve oil production.
- 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
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
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.
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
Automatic Well Test Process
OIL AND GAS DRILLING COMPANY
Improvements were needed to their automatic well test processes to increase test accuracy and productivity.
Crankshaft Production Failures
AUTOMOTIVE
Excessive crankshaft production failures
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.
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.
