Client
A leading Pacific Northwest refinery operator and aviation fuel supplier.
Glance
Implemented a structured Maintenance Control System (MCS) and contractor management framework for a major refinery, enabling improved maintenance productivity, stronger governance, and better cost control through enhanced work management processes.
Issue
The client sought to improve maintenance performance and operational efficiency by strengthening its Work Management governance and contractor management practices.
The engagement focused on increasing workforce productivity, improving maintenance planning and execution, enhancing performance visibility through structured KPIs, and establishing a sustainable Maintenance Control System (MCS) to support long-term operational excellence.
In addition, the client required a data-driven approach to optimize resource allocation, improve contractor utilization, and foster stronger collaboration between Operations and Maintenance teams.
Approach
The implementation of the MCS was designed around three core objectives:
Developing and implementing a structured Work Management governance system to enhance accountability and decision-making.
Defining and embedding key performance indicators (KPIs) to improve visibility into maintenance execution.
Assessing and optimizing the allocation of contractor work, targeting an annualized cost saving of $2 million.
The workstream was managed through an Agile framework using a digital project management platform, with daily stand-ups, bi-weekly sprints, and structured steering committee reviews. The 26-week project was delivered by a dedicated team comprising a project manager, a senior consultant, and a part-time data specialist, working alongside internal refinery stakeholders and a corporate Center of Excellence (CoE).
Engagement ROI
The governance system audit yielded a significant improvement, with an effectiveness score rising from 45% to 87%. Key performance indicators, including schedule attainment, unscheduled work rates, and backlog reduction, showed measurable progress. Most notably, the initiative fostered stronger collaboration between Operations and Maintenance teams, creating a unified approach to resolving performance challenges. These improvements have established a sustainable foundation for future maintenance optimization, positioning the refinery for long-term success.
