Cost reduction through lean methodologies on a critical downhole connection with a history of failures and downtime

Cost reduction through lean methodologies on a critical downhole connection with a history of failures and downtime

Client

A leading oil and gas service provider in the world.

Problem Statement

The client was facing complex manufacturing process, tight tolerances, and high non-conformance with a history of failures associated with well downtime, burnt electronics, and loss of electric integrity.

Benefits Achieved

Zero rejections, zero down time with consistency in welds, where anyone anywhere anytime can perform the weld with the same quality. >50% cost reduction due to simpler design and less physical tests while the product cost was brought down from $15,000 to $6,500, which translates to $0.5M annual savings, and more.

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