Streamlining material management during a $120M refinery turnaround

Background

PMM supported a $120M turnaround project at Phillips 66 in Carson, CA, managing over $30M in materials. The refinery faced challenges with material loss, inefficiencies, and lack of visibility during turnarounds, leading to cost overruns and delays.

Challenges

• Material loss and waste. Lack of accountability resulted in a 23% loss from theft, waste and mismanagement.
• Productivity issues. Workers had to leave job sites to retrieve materials, causing delays and reduced productivity.
• Labor costs. High labor costs with minimal output due to inefficient workflows.

Solutions implemented

1. EZTRAK integration. Deployed real-time inventory tracking with centralized reporting for material visibility.
2. Material kitting and tagging. Prepped and delivered kits directly to workers at job sites, eliminating downtime.
3. Optimized labor deployment. Reduced required labor by 33%, reallocating resources to high-value tasks.

Results

Cost savings

$6.9M

Material loss and waste reduced by 23%, in hard cost savings.

Labor efficiency

$200K

Saved by executing the same scope with two-thirds of the workforce.

Productivity gains

35%

Higher worker efficiency, cutting delays and increasing throughput.

Operational excellence

Benchmark

Seamless material management, setting the standard for future turnarounds.