Success Story: Fuel & Lubricant Manufacturer Saves $390K Annually

Client Overview

Facing rising demand and mounting pressure to increase output without expanding headcount, a Fortune 500 fuel and lubricant manufacturer turned to Adept for help. The company refines, blends, and distributes a wide range of petroleum-based products, but inefficiencies in their production line were limiting throughput. With no in-house experts to troubleshoot the issues and third-party manufacturing costs climbing, they needed a partner who could quickly assess, optimize, and deliver results.

Adept’s end-to-end optimization transformed operations with $390K in annual savings, record-breaking output, and lasting process improvements that enhanced both efficiency and team collaboration.

The Challenge

The client needed to scale their output, increasing production from 12,000 to 20,000 gallons per shift, without adding additional shifts or outsourcing more production. At the core of the problem was the multi-purpose line (MPL), which fills five different bottle types, including quart, gallon, and 5-quart containers.

However, the MPL was underperforming:

  • Filling equipment and a newly installed automated case packer were unreliable
  • Factory Acceptance Testing (FAT) had been minimal, revealing gaps too late
  • No subject matter expert was available to diagnose or solve performance issues
  • The plant had resorted to expensive third-party manufacturing to meet demand

The team was dealing with breakdowns, inconsistent performance, and a lack of clarity on where bottlenecks were occurring.

Our Approach

Adept partnered with the client’s internal team, collaborating with both union workers and leadership, to lead a comprehensive optimization project. The strategy was built around three core principles:

  • Stress-testing equipment to identify bottlenecks
  • Performing mechanical, electrical, and PLC upgrades
  • Repeating cycles of optimization until target speeds were met

Key Engineering Solutions Implemented:

  • Replaced and upgraded key components: Case erectors, lane driver, drop packer
  • Improved the de-palletizer stripper belt to reduce downtime from fallen bottles
  • Optimized case packer robotics: improved vacuum systems and rotation speeds to reduce bottle drop
  • Adjusted in-feed conveyor logic to reduce pressure and improve consistency

The Impact

Adept's end-to-end optimization delivered more than just higher numbers:

  • $390K in annual savings by eliminating third-party fill costs
  • 5,000+ gallons more per shift through process optimization
  • Production records broken across all key product lines
  • Improved collaboration between union teams and management
  • Repeatable system improvements for long-term efficiency gains

This isn't just a fix. It’s a transformation.

Let’s Talk Efficiency Gains

Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.

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