ENGIE’s 1,200 MW plant faced inefficiencies in GT outage planning, with a lengthy 65-day lead time and multiple non-value steps leading to significant labour waste.
We used lean optimization with Gemba walks, SIPOC analysis, and VSM. In addition, we eliminated 18 non-value steps, automated workflows, introduced parallel processing and integrated asset management with feedback loops.
This resulted in enhanced process accuracy and cross-functional alignment. Overall, it reduced the lead time by 86% which equates to 9 days and saved 88 man hours per cycle which equates to $1,100 USD / cycle / employee. In total, it freed up 2.75 months of labour annually, which totals $5,500 USD / year.
