$38B
Downstream
Driving $330M in EBITA Through Multi-Site Refinery Transformation
Industry: Oil & Gas, Sustainable Energy
Service: Logistics and Distribution
Service: Operational Excellence
Service: Operations Strategy and Transformation
Service: Supply Chain
Our Client
A $38B downstream refining and retail company operating a network of complex refinery sites across the United States with varying scale, technology, and operational maturity.
The Challenge
The organization faced mounting pressure to improve reliability, reduce costs, and increase returns on invested capital across a diverse network of refinery sites. While traditional best practices had been applied, performance improvements had plateaued, leaving the business unable to meet evolving operational and financial targets.
- Immediate need to improve plant reliability, effectiveness, and productivity
- Traditional best practices failing to deliver further performance gains
- Rising maintenance costs combined with declining productivity
- Inefficient and unsustainable contractor cost structures
- Low return on invested capital across sites
- Inconsistent performance across refineries with varying complexity
Real Results Achieved Together
A coordinated, enterprise-wide transformation unlocked significant financial and operational gains across all refinery sites.
$290M+
Annualized Benefits
$3M
Reduction in operating costs
$5M
Labor Savings
Transformation Impact
- $290+ in annualized benefits from best practice implementation
- $37M reduction in operating costs
- $47M in capital efficiency gains across three sites
- $5M turnaround labor savings (10% reduction) at one site
- 34 corporate initiatives delivered on time and under budget
Our Approach
- Implemented contractor cap and trade model to optimize labor cost and flexibility
- Deployed pull-based digital maintenance system to improve productivity and reduce backlog
- Introduced lean capital deployment framework to accelerate project execution and efficiency
- Optimized rail logistics operations to increase throughput and support higher sales volumes
- Standardized best practices across maintenance, operations, reliability, capital, and logistics
- Drove cross-site alignment to ensure consistent performance and scalability
- Partnered closely with leadership to embed sustainable operational improvements
Related Services
Operations Strategy and Transformation
Helping organizations rethink how they create value. We strengthen performance, build resilience, and accelerate growth across every layer of your business.
Supply Chain
Supplier complexity obscures 70% of your value creation. We strengthen networks through supplier development programs, risk mitigation strategies, and collaborative innovation platforms.
"
Coordinated, cross-site transformation is the key to unlocking sustained performance and financial impact in complex industrial networks.
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Facing Similar Challenges?
- Achieve top quartile refinery performance
- Reduce operating and maintenance costs at scale
- Improve capital efficiency and project delivery
- Drive measurable EBITA impact across sites
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