Benchmarks & Client Cases

Accelerated Plant Shutdown

The Challenge



• Summer shutdown maintenance with many inefficiencies and a lack of standards

• High manpower costs (80 external resources)

• Long duration (3 weeks)

Root Causes

• Spares/tools not ordered in advance

• Critical Plan not visible

• Tasks planned with a lot of safety (buffer)

• Little time invested in task and resource planning

The Solution


• Pull Planning with Time and Cost Buffers

• Visual Management Boards for work and KPI monitoring

• Spare parts stored near machines, and tool/consumable kits prepared

• Daily cost control

The Results

The project resulted in Annual Savings of $3.5 million.


Manpower cost reduction

Manpower costs reduced by 25%


Shutdown duration

Shutdown duration reduced by 10%


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