Client Success
Stories
We Do,
Stories Speak
Client success stories provide insights into how Kepner-Tregoe consulting and training services resulted in measurable improvements in targeted KPIs.
Client success stories are organized by industry, but many are relevant across industries because they illustrate dramatic results based on the application of analytic thinking to the problems, plans and decisions made by individuals and teams in our increasingly digitized and changing business environment.
NS BlueScope Malaysia Delivers a 16.1% Improvement
Challenge
The manufacturing staff of NS BlueScope Malaysia - an international producer and supplier of steel products - who perform root-cause analysis encountered issues during the metal coating process. The data gathered for troubleshooting was inconsistent with line leaders and workers’ explanation of manufacturing problems. Tracking the effectiveness of corrective actions was not visible, and the trigger to determine which of the various troubleshooting tools to use, i.e., Root Cause Analysis (RCA), Fishbone, Problem Analysis (PA), was unclear.
Result
KT conducted a diagnostic on the root cause analysis (RCA) process and identified strengths as well as areas for improvement in troubleshooting work-flows. This initiative helped create major improvements in downtime and line stops and the reduction of speed loss increased availability. Metal Coating Line OEE performance showed an increase from 77.66% to 90.17% from one year to the next. A 16.1% positive change.
Dramatic Improvements at North America’s Largest Power Plant
Challenge
Facing growing operational problems and environmental concerns the plant needed to make rapid, dramatic improvements. Plant management initiated a major improvement initiative, collaborating with Kepner-Tregoe (KT ) to address a series of operational improvements.
Result
Over 100 formal and many expedited process exercises resulted in sweeping improvements, millions of dollars in savings, and better environmental standards. Some examples included when the plant became dependent on rented compressed air systems to meet demand, a team used KT Decision Analysis (DA) to find a better alternative. Annual savings are $160K, reliability has increased, and environmental hazards reduced.
A Rapid Solution Preserves Revenue & Reduces Cost
Challenge
The opportunity to use the new KT approach arose at a plant when a recurring overheating problem developed in a compressor that fluidizes Cu-Al catalyst inside a reactor and recycles unconverted gases. The compressor was shutdown as a safety measure while the overheating problem was resolved.
Result
The compressor was brought online quickly, minimizing expensive downtime. Shutdowns can quickly reach $1 million in lost revenues. This was the first of many successful applications of KT process that have proved valuable in avoiding costly recurring problems, pursuing ongoing improvements and making cost-saving modifications.
Network Rail
Challenge
When new cables showed poor insulation resistance readings on the final installation test, up to 1000m of cable had to be replaced in several locations. Some projects had to pay for replacement cables, doubling costs - others delayed installation, slipping project timescales. The cable distributor had to test cables on site before Network Rail allowed their use. The quality issue presented in poor readings, deformation of the outer cable sheath, or deformation of the inner conductor.
Result
- Preventing defective product at a supplier site is challenging, but auditing with KT Problem Analysis provides assurance that existing quality issues are resolved properly. - Risk of quality issues for £17 million worth of cable reduced - Supplier’s ability to find root cause confirmed - Future recurrences avoided - Proper corrective actions taken
Foil in the Brake Valve Inlet Filters
Challenge
When reports of "spongy" parking brakes on cargo planes began, it was not a threat to safety or service. But with growing frequency, maintenance checks revealed what appeared to be pieces of foil in the filters that keep the hydraulic fluid clean. The foil particles trapped in the filter almost blocked the flow of hydraulic fluid, causing the brakes to feel spongy. Early speculation that contract maintenance crews were introducing the foil by not using proper sealing caps during maintenance checks proved to be wrong: the root cause of the clogging remained unknown.
Result
After days of troubleshooting failed to find root cause, the problem was referred to the company’s own Kepner-Tregoe rational process experts, Program Leaders (PLs) who are certified to teach and facilitate KT Problem Solving & Decision Making, a structured approach to rapid issue resolution. They quickly developed an effective problem statement and examined the “IS” and “IS NOT” data. It became apparent that they needed to know where else this was happening in the world. Once they had this information, the solution quickly followed.
Why KT?
Run More Efficiently
KT will help you to clarify and remove recurring and
high-impact issues, supporting smoother and more
cost-efficient business operation.
Confidence Under Pressure
KT's unique critical thinking methods are designed to
support you in situations of maximum stress. When it
really matters that you find the best solution, the KT
toolkit is proven to deliver.
Process Plus Experience
KT consultants have a wealth of experience in
supporting clients use of the KT methods in a wide
variety of industries and situations. We can help you
get the maximum value from deploying the KT
toolkit.
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