98%
Preventive maintenance compliance
Transforming Tank Farm Maintenance to Unlock $10M Savings: Enhancing Reliability, Safety, and Operational Performance
Industry: Oil & Gas, Sustainable Energy
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: People and Organization
Our Client
A leading refinery facing siloed operations, ineffective maintenance processes, and cultural resistance to change within its tank farm operations.
The Challenge
The refinery’s tank farm operations were hampered by both structural and cultural issues:
- Ineffective inspection programs caused frequent rework and safety concerns.
- Safety risks exacerbated by a reactive culture and inconsistent accountability.
- Resistance to change among middle management and operational teams slowed adoption of new practices.
- Limited collaboration due to reliance on legacy approaches and siloed functions.
Real Results Achieved Together
Through an integrated approach addressing both culture and structure, EFESO helped the refinery achieve substantial improvements in maintenance performance, safety, and operational efficiency.
60%
Reduction in tank farm maintenance backlog
$10M
Annual OPEX savings
90%
Overall schedule compliance
Transformation Impact
- Launched Rapid Improvement Teams and Loss Elimination Boot Camps to tackle priority issues.
- Integrated reliability and maintenance functions into a single department to break down silos.
- Introduced focused KPIs, dashboards, and Command Center meetings to track performance.
- Systematically reduced maintenance backlog while strengthening preventive maintenance compliance.
- Fostered a culture of shared ownership, collaboration, and continuous improvement.
Our Approach
EFESO applied a holistic program combining cultural change, structural optimization, and operational discipline:
Rapid Improvement & Loss Elimination
- Created cross-functional teams to address critical maintenance challenges.
- Conducted targeted boot camps to identify and eliminate recurring losses.
Organizational Restructuring
- Merged reliability and maintenance teams into a unified department.
- Promoted shared accountability and collaborative problem-solving.
Process & KPI Implementation
- Analyzed critical equipment and systems to define priorities.
- Established KPIs, dashboards, and weekly/monthly performance reviews.
- Implemented Command Center meetings for structured performance oversight.
Backlog Reduction & Operational Discipline
- Reviewed and reduced maintenance backlog systematically.
- Strengthened preventive maintenance scheduling and adherence.
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Facing Similar Challenges?
- High maintenance backlog affecting reliability and operational performance.
- Safety risks due to ineffective inspection programs.
- Seeking structured KPI-driven maintenance and cultural transformation for sustainable results.
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