ASSESS

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PAVING THE WAY TO OPERATIONAL EXCELLENCE.

 

The assess phase is all about identifying & quantifying problems, with the support of data. Taking a holistic view of all operations from goods-in to finished product.

 

Our audit identified significant scope for improvement in the following areas:

 

-Visual Management

-Standards

-Efficiency

-Maintenance

-Training

SUSTAIN

DEVLOPING A CONTINUOUS IMPROVEMENT CULTURE

 

Improvements can only occur once performance is measured. We created digital & automated KPI dashboards for production - KPIs were carefully selected to align with strategic aims and motivate teams on metrics they had direct influence over.

 

Operators now have daily CI huddles, review their key metrics and uncover additional improvement opportunities.

 

Through Lean Six Sigma training, we aligned teams with what ‘best-in-class’ looks like - helping promote engagement and giving confidence to team leaders to solve the problems most critical to their area KPIs.

Continuous Improvement/ Operational Excellence Transformations in Oil & Gas

INTODUCTION

How FlowPlus have helped clients in the oil & gas industry transform their operations to work in a smarter, leaner way.

FlowPlus believes every organisation can improve. Having worked with over 50+ global clients across multiple industries we are specialists in operational excellence & continuous improvement in the Oil & Gas Industry.

 

Using the foundations of lean manufacturing as our driving principles, we work with our clients to transform company cultures, reduce costs, improve output, reduce downtime and equip your Organisation to better solve future problems that arise.

 

Typical benefits can be split into 2 distinct categories – Bottom Line Results & Cultural Changes.

 

Working closely with operations, maintenance and leadership teams we help translate strategic plans & targets into action. Rolling up our sleeves, we implement the solutions needed to realise your full potential.

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THE FLOWPLUS TRANSFORMATION PROCESS

The 3-step FlowPlus transformation cycle is a tried & tested way to achieve sustainable, long-term results. Following the transformation cycle, FlowPlus & our client worked as one-team on the journey towards Operational Excellence.

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ASSESS

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WORKING AS ONE-TEAM

Our client's transformation process started with a thorough assessment phase to uncover areas for improvement and gain insight into current practices.

Working as one team, we collected data, observed operations, spoke with operators & maintenance and mapped the main processes. Using specialist tools we transformed data into insights, uncovering large untapped improvement opportunities that reduced process waste, maximised productivity & developed smarter ways of working.

IMPROVEMENT STARTS WITH DATA.

 

We make data-driven decisions, using facts and insights to guide our solutions.

That’s why we have confidence we can make such a big impact.

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PAVING THE WAY TO OPERATIONAL EXCELLENCE.

 

The assess phase is all about identifying & quantifying problems, with the support of data. Taking a holistic view of the entire operation, we gathered facts, analysed past data and used AI & machine learning to draw insights. Our analysis identified significant improvement potential with our clients maintenance strategy and execution. The key metrics for improvement were identified as being both lagging and leading indicators:

 

Downtime – Level I trips, Level II trips, Shutdowns, OPE (overall plant effectiveness)

Maintenance performance – HOTT (hands-on-tool-time), MTTR, MTBF, # PM activities/day

Maintenance/warehousing costs – Spare parts management costs, Cost of critical spares, RPN for critical equipment, time to locate product.

 

 

Once all the improvement opportunities had been identified we developed a transformation roadmap – prioritising the most impactful projects on their journey to Operational Excellence.

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IMPLEMENT

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EXECUTING THE ROADMAP

 

Following the transformation roadmap outlined in the assess phase, the projects with greatest impact were launched. (These can vary significantly for different clients)

 

1.OPE improvement workshops

2.Lean Maintenance Strategy Deployment

3.Warehouse Optimisation (spare parts management)

4.Optimised Permit-to-work system

5.Continuous Improvement Structure & Culture Development

OPE – OVERALL PLANT EFFECTIVENESS

 

Within the manufacturing & automotive industry OEE is a well known and carefully monitored metric – identifying the overall equipment effectiveness of critical machinery. Measuring OEE enables improvement opportunities to be identified and problem-solving workshops launched to reduce losses, maximise output, reduce operating costs and eliminate unplanned downtime. Within the process industry FlowPlus use OPE (overall plant efficiency) to evaluate the production of an entire LNG plant compared to its full potential. By carrying out a thorough assessment and collating data we can provide a live OPE value – uncovering the reasons for any losses.

 

Once we know where the losses are put in place countermeasures to reduce re-occurrence and target the root cause of each problem. By implementing a Lean Maintenance strategy, maintenance costs are greatly reduced, equipment functions with a longer life-cycle and unexpected losses are greatly reduced.

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REAL RESULTS MEASURED

 

We don’t count our days on-site; we judge our success by our results.

 

Increasing the hands-on-tool time by over 75% was only possible by making significant changes to current processes.

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STRUCTURED PROBLEM SOLVING

 

Our Consultants operate around the globe – working directly with your teams to establish continuous improvement routines & the structure needed to allow improvements to be identified and raised from the ground up. A shift from fire-fighting to ‘root cause problem solving’ is achieved and the company culture transforms to become a true learning organisation.

SUSTAIN

DEVLOPING A CONTINUOUS IMPROVEMENT CULTURE

 

Improvements can only occur once performance can be measured. That is why provide every team with a performance board – showing their daily work plan, KPIs, improvement opportunities & strategic aims. Now operators have daily CI huddles, review their key metrics and uncover additional improvement opportunities. Working closely with the client, we trained all supervisors to hold these effective daily meeting, engage all team members and promote a continuous improvement culture in everything they do.

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AUTONOMOUS PROBLEM SOLVING

 

Within the first month of introducing daily CI huddles with team KPIs, 20 initiatives have been launched and results are already improving. Identified by one of the operators – a new process for checking in stock in the warehouse has saved an estimated 150 hours manual handling per week.