RCM 2 Industry Benefits

  • $12,000,000 annual revenue improvement through increased reliability in an oil refinery
  • Reduction in annual waste valued at $1,000,000 in a paper machine
  • Savings of $5,500,000 in lost tons and elimination of fixed-interval overhauls at a major integrated steel works
  • Downtime reduction amounting to over $300,000 in annualized savings in a food packaging line
  • A 62% reduction in low frequency maintenance tasks in an automotive machining line
  • A $700,000 annual batch loss reduction in a pharmaceutical plant
  • Decrease in reactive maintenance costs of $200,000 in a bulk chemical process
  • A $1,000,000 cost of downtime reduction in an electric substation
  • 23% improvement in packaging line efficiency for a pharmaceutical plant
  • Avoidance of $5,000,000 in catalyst replenishment costs in a refinery
  • Line efficiency increased from 62% to 90% in a food processing plant
  • An annual $10,500,000 dollar revenue increase due to improved availability on off shore oil platforms
  • Reduction in start-up time after a process redesign from the typical 3 weeks to 4 days, resulting in a $3,000,000 revenue increase for an automotive supplier
  • Food plant product quality complaints dropped from 12 per month to zero
  • Elimination of all ship loading delay penalties saving $2,000,000 annually in a refineries coke loading operation
  • Generated a maintenance strategy that reduced the risk of injury to less than 1 in 100,000,000
  • $3,000,000 in capital cost avoidance in a pharmaceutical plant
  • $150,000 reduction in annual pump overhauls in a electric utility
  • Increase in revenues of $2,000,000 due to the elimination of an annual two-week shutdown
  • Reduction in planned shutdowns by 33%, resulting in a $500,000 annual production gain
  • 40% reduction in roll change lost time in a rolling mill
  • $200,000,000 annual throughput increase in oil distribution stations.
  • Reduction of substation outages resulted in $100,000,000 in increased downstream plant uptime
  • Risk of an evacuation system not working when needed reduced to less than 1 in 30,000,00