Lean Kaizen in Oil & Gas Industry

• Recast OEE for filling lines and blenders to show clear availability, performance and quality losses at equipment level.
• Use TPM and Autonomous Maintenance to reduce breakdowns, jams and chronic minor stoppages across conveyors, carousels, pumps, weighing scales and sealing units.
• Apply SMED concepts on changeovers between pack sizes/grades to cut set-up time and stabilise start-ups.

• Map complete changeover cycles (drain, flush, clean, set-up, trial, ramp-up) at a detailed task level.
• Separate online vs offline activities; parallelise tasks where possible and eliminate non-value-adding steps.
• Optimise flushing standards and cleaning practices to minimise product loss while maintaining quality.

• Analyse production variance, rework and rejects at SKU, Standardise blending and filling parameters (agitation times, temperatures, fill weights, torque, leak tests) to improve Right-First-Time (RFT).
• Use root cause analysis and FMEA to prevent recurring failures in blending quality and filling accuracy.

• Redesign FG and packaging warehouses using Runner, Repeater, Stranger analysis and SKU-wise sales data to set clear min–max norms.
• Create dedicated, visually marked locations for high movers, slow movers and overflows; streamline receiving, picking and dispatch routes.
• Integrate production planning and warehouse capacity planning to avoid excess FG build and stock-outs.

• Apply OEE analysis to filling carousels, washing/drying units, leak-test stations and truck loading to quantify true capacity.
• Use Focused Improvement on high-frequency losses: cylinder jams, chain cuts, loading-man delays, pressure drops and weighing issues.
• Standardise Autonomous Maintenance and inspection routines (conveyors, stoppers, washing/drying, valves, leak testers) to catch early abnormalities.
• Analyse truck loading data to identify bottlenecks and redesign dock processes for faster, more consistent turnaround.

• Improve reliability of compressors, liquefiers, vaporizers and filling manifolds via TPM and critical equipment monitoring.
• Reduce RM – Cylinder losses with Root cause analysis
• Streamline cylinder/cryogenic tank movement, loading and documentation to reduce turnaround times and errors.
• Standardise safety checks (valves, connections, leak tests) and visual controls for high-pressure operations.

Lean Kaizen helps gas plants increase effective capacity without immediate capex, while strengthening compliance and incident prevention.