Chevron’s Pembroke refinery has a reputation as being one of the best for reliability performance and recognising the impact a major failure would have on production, it engaged Reliable Manufacturing to help establish a sustainable reliability programme.

An Operations Excellence Master Class facilitated by Reliable Manufacturing helped identify a number of key areas where improvement could be made, and inspired the refinery’s senior management team to intensify its focus on defect elimination. Led by Project Manager, Richard Allen, the company established ‘project PRIDE’; Pembroke Refinery Implementing Defect Elimination.

The project is part of a strategic initiative to raise the importance of operational discipline and to ensure operations and maintenance staff complete ‘every task the right way, every time’, thus improving reliability, efficiency and safety at the refinery.  Richard Allen says the impact has been remarkable.

“The work ethic and communication between teams has been first class and we’ve made some significant improvements already,” he says.  “We believe we’ve now got the best lube oil management system within Chevron and are probably starting to hit world class standards.  We’ve reduced lube oil usage, and the meantime between failures of seals and bearings has improved significantly, which means we’re getting greatly improved equipment efficiency too.”

The Operations Excellence Master Class focuses in particular on the way processes and equipment are designed, operated and maintained.  “The Master Class has really encouraged ownership of the plant amongst the workforce and helped establish the importance of care and restoration of their machinery,” says Reliable Manufacturing’s Managing Director, Andrew Fraser.

Chevron intends to put all 300-plus operations and maintenance staff at the refinery through the Master Class programme over the next 18 months, but Allen says that even amongst those that have not yet attended, there is evidence of behaviour change as a result of the PRIDE project.  “There’s definitely been a knock-on effect,” he says. “People see others taking greater care of equipment and calling in maintenance less often, so they start to do it too.  People are taking the initiative; going the extra mile. It’s transforming the culture of the workforce,” he concludes.

The next public Operations Excellence Master Class is scheduled for April 22nd in Runcorn.  For more details please see the website:

Upcoming Events

August 9 - August 11 2022

MaximoWorld 2022

View all Events
80% of newsletter subscribers report finding something used to improve their jobs on a regular basis.
Subscribers get exclusive content. Just released...MRO Best Practices Special Report - a $399 value!
Three Things You Need to Know About Capital Project Prioritization

“Why do you think these two projects rank so much higher in this method than the first method?” the facilitator asked the director of reliability.

What Is Industrial Maintenance as a Service?

Industrial maintenance as a service (#imaas) transfers the digital and/or manual management of maintenance and industrial operations from machine users to machine manufacturers (OEMs), while improving it considerably.

Three Things You Need to Know About Criticality Analysis

When it comes to criticality analysis, there are three key factors must be emphasized.

Turning the Oil Tanker

This article highlights the hidden trap of performance management systems.

Optimizing Value From Physical Assets

There are ever-increasing opportunities to create new and sustainable value in asset-intensive organizations through enhanced use of technology.

Conducting Asset Criticality Assessment for Better Maintenance Strategy and Techniques

Conducting an asset criticality assessment (ACA) is the first step in maintaining the assets properly. This article addresses the best maintenance strategy for assets by using ACA techniques.

Harmonizing PMs

Maintenance reliability is, of course, an essential part of any successful business that wants to remain successful. It includes the three PMs: predictive, preventive and proactive maintenance.

How an Edge IoT Platform Increases Efficiency, Availability and Productivity

Within four years, more than 30 per cent of businesses and organizations will include edge computing in their cloud deployments to address bandwidth bottlenecks, reduce latency, and process data for decision support in real-time.

MaximoWorld 2022

The world's largest conference for IBM Maximo users, IBM Executives, IBM Maximo Partners and Services with Uptime Elements Reliability Framework and Asset Management System is being held Aug 8-11, 2022

6 Signs Your Maintenance Team Needs to Improve Its Safety Culture

When it comes to people and safety in industrial plants, maintenance teams are the ones who are most often in the line of fire and at risk for injury or death.