Application of Lean to Improve Maintenance Productivity & Efficiency of an Oil Company in the UAE

Abstract

This research aims to optimize Maintenance Wrench Time in an oil and gas company in the UAE using the Lean Six Sigma (LSS) DMAIC framework. The study seeks to address excessive overtime costs and inefficiencies in the maintenance department by eliminating non-value-added activities and improving overall productivity. Design/methodology/approach – The study employs the LSS DMAIC methodology, integrating various tools and techniques to systematically improve the maintenance process. The approach involves defining the problem, measuring current performance, analyzing data to identify root causes of inefficiencies, implementing improvements, and controlling the process to sustain gains. A combination of self-reporting and Day-In-the-Life-Of (DILO) methods was utilized for accurate wrench time measurement. Findings – The implementation of the LSS framework significantly improved wrench time efficiency, with notable reductions in overtime and non-value-added activities. The study demonstrates the effectiveness of the DMAIC approach in identifying and eliminating inefficiencies, resulting in a 17% improvement in wrench time from 34% to 51% and substantial cost savings. The introduction of a Power BI tracking system for real-time monitoring and analysis was a key innovation, enhancing the visibility and management of maintenance activities. Research limitations/implications – While the study provides valuable insights into wrench time optimization in the oil and gas sector, its findings are based on a single case study. Future research could explore the application of the framework across different industries and incorporate additional Lean tools and techniques to further enhance its effectiveness. Practical implications – The research offers a practical framework for maintenance wrench time optimization using LSS DMAIC tools, demonstrating significant improvements in efficiency and cost savings. The study underscores the importance of management commitment and continuous improvement culture in sustaining operational excellence. Originality/value – This study contributes to the sparse literature on the application of LSS methodologies to wrench time optimization in the oil and gas industry. It presents a novel approach to addressing maintenance inefficiencies, supported by the successful implementation of a real-time tracking system, providing a model for similar initiatives in various operational contexts.

Date of Award	2 May 2024
Original language	American English
Supervisor	Maher Maalouf (Supervisor)