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Valero McKee

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Background: 

  • Refinery with throughput capacity in excess of 150,000 BPD
  • A varied product range
  • More than 400 employees
  • Lack of Planning and Scheduling, Coordination between Crafts & between Maintenance and Operations

Process Results:

  • Developed and implemented Work Management
  • Reduced Backlog of Maintenance Work Orders from 3500 to 1500
  • Reduced Emergency (Priority 1) work orders from over 25% to about 10%
  • Training and documentation to ensure sustainability including roles and responsibilities, process flows and procedures
  • KPIs to monitor and track results

Bottom-Line Impacts:

  • Reduced monthly Routine Maintenance Contractor Usage from 3MM to 1MM
  • Improved Environmental Performance – averaged 54 incidents a year  for the last three years -14 through September 2008
  • Increased monthly profitability by  over 30MM per month

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