⚙️ Energy Producer – Refinery Turnaround Optimization

 

Challenge: 

A major energy producer faced rising refinery turnaround costs, declining contractor productivity, and increasing operational disruption. Expanding work scopes, poor planning, and reactive maintenance created site congestion, extended downtime, and reduced plant reliability

 

​Execution

Kria Advisors led a detailed operational and cost diagnostic across maintenance, contractor performance, and asset lifecycle economics.

• Assessed contractor productivity, rework, and warranty-driven failures

• Analyzed turnaround execution, scheduling inefficiencies, and congestion drivers

• Evaluated total lifecycle cost of critical equipment and sub-assemblies

The work exposed a “fix-only-when-broken” maintenance culture and fragmented planning discipline.

Kria Advisors worked with operations and maintenance leadership to:

• Implement contractor performance scorecards and accountability mechanisms

• Shift repair and maintenance work to non-peak periods to reduce congestion

• Improve long-lead procurement planning, including critical spares

• Introduce lifecycle cost management across key capital assets and components

 

Impact:

• 12% reduction in annual turnaround costs

• Improved contractor performance and reduced rework

• Increased plant reliability and throughput

• Established lifecycle cost discipline across critical assets

 

Transform reactive maintenance toward structured lifecycle cost management—improving both operational performance and capital efficiency.​