Title: Improvement of refinery maintenance and mechanical services: application of lean manufacturing principles

Authors: Boppana V. Chowdary; Kuldeep Ojha; Arlene Alexander

Addresses: Department of Mechanical and Manufacturing Engineering, The University of The West Indies, St. Augustine, Trinidad and Tobago ' Department of Mechanical and Manufacturing Engineering, The University of The West Indies, St. Augustine, Trinidad and Tobago ' Department of Mechanical and Manufacturing Engineering, The University of The West Indies, St. Augustine, Trinidad and Tobago

Abstract: Purpose: The aim of this paper is to show a successful improvement in operations with the implementation of lean manufacturing strategies in a Caribbean oil and gas company. Design/Methodology: Initially, a review of literature was performed on lean manufacturing (LM) tools. Then interviews and GEMBA walkthrough was carried out in the selected case organisation followed by the problems faced were analysed using value stream map (VSM) together with root cause analysis tools. At the end, future state VSM was developed and the benefits due to implementation of LM principles were quantified. Findings: The study revealed that a traditional approach is currently being used on the shop floor thus increasing the opportunity for hidden wastes between the processes as well as increased repair time due to defective equipment. The results concluded that improved shop floor utilisation, reduction in preparation time and hidden wastes were identified on the shop floor. Originality/value: The review of literature indicated that implementation of the lean principles in the Caribbean oil and gas sector has not been explored. Further, the study results provide a road map for similar organisations to achieve operational improvement but also is valuable for academic and research community for practical implementation of lean principles.

Keywords: lean; MRO; maintenance; repair and overhaul; maintenance repairs; efficiency; wastes; 5S; VSM; value stream map.

DOI: 10.1504/IJCENT.2018.092082

International Journal of Collaborative Enterprise, 2018 Vol.6 No.1, pp.20 - 36

Received: 07 Jun 2017
Accepted: 01 Aug 2017

Published online: 31 May 2018 *

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