Time-on-Tools
Downstream
Value Preservation
Case Study · In Depth
Time-on-Tools Optimization
A refinery maintenance team was losing wrench-time to poor work-order sequencing and idle wait time between jobs.
The Challenge
Idle, Rising OPEX
Technicians spent more time waiting on parts, permits and instructions than actually turning wrenches — and maintenance OPEX kept climbing despite headcount staying flat.
Our Approach
Time-on-Tools Reengineered
We mapped the full work-order lifecycle, removed the sequencing bottlenecks, and rebuilt the handoffs between planning, permitting and execution so crews arrived at the job already able to start.
The Result
23% → 56%
Wrench-time on tools more than doubled — more actual repair work, less waiting, without adding a single additional technician.
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