4,000% ROI Using TapRooT® to Improve Process Reliability
A TapRooT® User Success Story
Written by Jeremy Esquivel of the
Acrylates Area Reactor Trip Reduction Team
This success story was written in the past and is being updated to our most recent blog article format and being posted here.
Our Acrylates Area Oxidation Reactor was experiencing frequent unplanned shutdowns (trips) that were causing losses of large fractions of our plant capacity. Previous corrective actions seemed to have little lasting impact. Our challenge was to form a team of operators, mechanics, and an engineer and come up with ways to reduce and eventually eliminate these unnecessary shutdowns.
A team was formed to study the problem. We decided that we needed better data (not conjecture) to study the reasons for the plant unreliability. We had heard about the TapRooT® System and so the whole team attended a public 2-Day TapRooT® Root Cause Analysis Course.
After the course, we went back and started performing a root cause analysis of each reactor trip. Using the root cause information, we developed solid corrective actions for each problem. We also collected statistics (a rolling three-month average) about the causes of the shutdowns and looked into the Generic (systemic) Causes for the top three causes and developed additional systemic corrective actions for these.
In less than 12 months we saw a constant, dramatic improvement in our plant reliability. Due to the reduction of the number of shutdowns and the estimated capacity available with improved reliability, in the first two years, we saved about 40 million dollars. These savings will continue to accumulate so the total saved will be even more. We believe that in the first two years our investment in TapRooT® and the investigation produced over a 4,000% return on our investment.
Besides saving money, our team received the highest corporate award possible for these improvement efforts. It easy to see why we believe that learning and using the TapRooT® System is an excellent investment.