Exergy Solutions partnered with a major oil sands operator to deliver a series of continuous improvement (CI) initiatives aimed at enhancing safety, reducing costs, and increasing operational efficiency. Using Lean Six Sigma methodologies and a collaborative, data-driven approach, Exergy worked closely with frontline teams to identify and implement practical solutions with measurable results.

One CI project focused on the elimination of unnecessary pipeline heaters during winter operations. By applying CI tools such as charters, metric graphs, and root cause analysis, the team identified opportunities to remove redundant equipment. This resulted in over $1.2 million in cost avoidance, significant reductions in greenhouse gas emissions (equivalent to taking 272 cars off the road), and improved safety by minimizing field exposure for personnel.

Another initiative addressed recurring incidents involving power poles across a large mining site. Through detailed incident analysis and stakeholder engagement, Exergy facilitated updates to signage, standards, and training. These improvements led to an incident-free period of over 250 days, all achieved with a modest investment of $2,000.

Supply chain delays were also tackled through a Kaizen event, where order and delivery data were analyzed to streamline processes. The team successfully reduced material lead times from three months to just ten days, generating approximately $1 million in savings and freeing up nearly 2,000 hours of productive time for frontline staff.

In a turnaround (TA) optimization project, Exergy mapped the entire value stream for a major vessel maintenance event. By re-engineering procedures and fostering cross-functional collaboration, the team reduced execution time by 300 hours, saved $1 million per turnaround, and achieved a $13.3 million cost avoidance by extending maintenance intervals.

Exergy’s CI capabilities are rooted in empowering client teams, fostering a culture of ownership, and delivering sustainable, high-impact results.