一个快速的解决方案保留了收入并减少了成本

石油和天然气

客户

An initiative to control costs at this multibillion-dollar company’s refineries and petrochemical plants included a management program designed to build issue resolution skills and embed a common problem solving process. The organization wanted to improve its effectiveness at performing root cause analysis and preventing recurring problems. Managers and engineers received Kepner-Tregoe (KT) Problem Solving and Decision Making training and began integrating the KT approach into issue resolution and improvement initiatives.

挑战

一个工厂出现了使用新的KT方法的机会,当时一个在反应器内流化铜铝催化剂并回收未转化气体的压缩机出现了反复的过热问题。在解决过热问题的同时,作为一项安全措施,压缩机被关闭了。

解决方案

The troubleshooting team used KT Problem Analysis to focus on the relevant data. This revealed that a faulty bearing had caused the overheating. In the past, the preliminary response was to replace the dry gas seal, a $75,000 process. This time, the team took only the necessary actions and used a new process to replace only the $7,500 bearing. In addition, the team determined that bearing reliability is not only a function of bearing quality but also of bearing orientation within the compressor.

结果

压缩机迅速上线,最大限度地减少了昂贵的停机时间。停机可以迅速达到$1万美元的收入损失。这是KT工艺的许多成功应用中的第一个,事实证明,在避免昂贵的重复问题、追求持续改进和进行节约成本的修改方面,KT工艺是有价值的。

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