$2.5M
Value Unlocked
Reducing Tank Turnaround Time and Unlocking $2.5M Through Kaizen and Process Simplification
Industry: Oil & Gas, Sustainable Energy
Service: Operational Excellence
Service: Transactions and Turnaround
Our Client
A large U.S. refinery operated by a leading energy company managing complex tank maintenance and cleaning operations across multiple teams and contractors.
The Challenge
The refinery faced persistent delays, cost overruns, and inefficiencies in its tank maintenance and cleaning program. Poor coordination across planning, procurement, operations, and execution teams limited visibility and slowed decision-making, making it difficult to execute work efficiently and consistently.
- Misalignment between planning priorities and execution needs
- Long contractor bidding and approval cycles (2–3 months)
- Slow decision-making driven by MOC processes
- Inefficient cleaning methods and equipment usage
- Inconsistent use of existing contractor agreements
- Limited coordination across cross-functional teams
- Lack of visibility between field execution and leadership expectations
- Minimal use of parallel work to reduce downtime
Real Results Achieved Together
A focused Kaizen effort rapidly simplified processes, reduced downtime, and unlocked significant value.
40%
Reduction in downtime
30%
Streamlined process steps
52
Issues resolved
Transformation Impact
- $2.5M in recovered value through faster turnaround and reduced delays
- 30–40% reduction in tank downtime
- 30% reduction in process steps
- 52 pain points and barriers identified and addressed
- 5.5 months of downtime recovered on diesel tanks
Our Approach
A focused Kaizen initiative enabled the refinery to simplify its tank maintenance process, eliminate delays, and improve cross-functional alignment. By bringing together stakeholders from across the organization, the team was able to identify inefficiencies and rapidly implement practical, high-impact solutions.
- Led a 5-day Kaizen event with 40+ cross-functional stakeholders
- Mapped the full process from shutdown to return to service
- Identified 50+ pain points and sources of delay
- Developed and executed 33 targeted improvement actions
- Standardized use of contractor frame agreements
- Integrated agreements earlier into procurement processes
- Enabled parallel work by starting known repairs ahead of final inspections
- Introduced improved cleaning strategies to accelerate turnaround
Related Services
Transactions and Turnaround
High-stakes situations demand rapid, decisive action. We stabilize and transform through operational diagnostics, cash flow optimization, and sustainable restructuring programs.
Facing Similar Challenges?
- Reduce downtime through process simplification
- Accelerate maintenance and turnaround execution
- Improve cross-functional alignment and visibility
- Unlock value through Kaizen-driven transformation
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