Closing the Loop on KPI Benchmarking Gaps
Benchmarking is an essential tool for evaluating asset performance, but for many operators, the path from data to value remains unclear. Benchmarking reports often land with fanfare, then stall without action.
The metrics are clear. The gaps are documented. But what’s the next step?
That’s where Becht’s BRAVO-BGC (Business Gap Closure) program comes in. Built by operators for operators, BRAVO-BGC transforms benchmarking data into tangible results through a proven, structured approach facilitated by experts who have done this before.
The Challenge: Great Data With No Action Plan
Most benchmarking studies surface performance gaps, but they don’t prioritize which gaps matter most, what actions to take, or how to embed change in the organization. The result is missed value. This gap between diagnosis and delivery is exactly what BRAVO-BGC is designed to close.
A Structured, Cross-Functional, and Outcome-Focused Approach
Becht’s BRAVO-BGC methodology guides clients through five phases of performance improvement:
- Prework – Assemble the right team, review initial benchmarking and performance data, and define the scope.
- Gap Assessment – Analyze KPIs, conduct field observations and interviews, and map the current state.
- Tactic Development – Quantify the cost/benefit of improvement opportunities, define required resources, and prioritize actions.
- Implementation Support – Develop detailed execution plans, track progress, and reinforce through coaching and workshops.
- Sustainability – Embed change management practices and feedback loops to keep improvements on track.
Where It Works: Multidiscipline, Multi-Site Success
Becht has applied this approach at sites around the world, with measurable results across a range of workstreams.
Reliability, Maintenance & Turnarounds
- A $45M opportunity was identified at a North American site by optimizing major maintenance strategy, redesigning organizational structure, improving preventive maintenance (PM) quality, and enhancing materials management – reducing craft labor demand by 30%.
- At a European site, $40M in improvements were unlocked by refining the maintenance strategy, strengthening reliability programs, managing critical spares, and reducing contractor rework. Ultimately, a 40% reduction in craft labor demand was achieved.
- A $17M opportunity was identified at a Latin American site by improving planning and scheduling practices, implementing a prioritization process, and establishing a dedicated maintenance supervisor role, which increased schedule compliance by 15% and reduced emergency work by 10%.
- Through better field materials handling, warehouse management, and maintenance planning, a North American site identified a $7M improvement – boosting productivity by 25%, cutting emergency work by 20%, and increasing schedule adherence by 53%.
Strategic Business Planning and Process Engineering
- At a Latin American refinery, Becht supported a holistic hydrocarbon loss reduction strategy worth $8M, implementing an action plan over one year to sustainably reduce losses by 0.3%.
- A collaborative project with a client identified $200M in opportunity by analyzing energy, process, and reliability gaps – delivering a $0.50/bbl increase in net cash margin through targeted implementation.
- A $26M value uplift was identified at a Latin American site by closing gaps in optimization work practices and aligning process improvements with the client’s digital strategy, improving net cash margin by 5%.
Energy
- At a North American site, Becht supported energy and emissions reduction planning that identified a 20% reduction in CO₂ emissions by prioritizing implementable energy-saving opportunities.
- In Europe, Becht identified 50+ opportunities and completed detailed technical and economic analyses on over 15 projects, leading to a $12M/year improvement in net cash margin following capital investments.
The Time for Action Is Now
The timing for KPI benchmarking and gap closure couldn’t be more relevant. With margins under pressure and new benchmarking results released, refineries need credible plans – not just data.
What we’re hearing from operators includes:
- “We know where we rank. Now we need to know how to improve.”
- “We’ve seen these KPIs before, but never with a roadmap to close the gaps.”
- “We’re ready to move from benchmarking to business value.”
Ready to Close the Gaps?
Becht brings independent, cross-functional expertise to help clients focus on what matters most. Our teams include specialists in process engineering, capital planning, reliability, and asset management, with deep familiarity in using benchmarking studies and site data to drive action.
Whether your priority is OPEX, reliability, energy intensity, carbon emissions, or Net Cash Margin, Becht helps you translate KPIs into tactical, high-value improvements tailored to your organization’s structure, systems, and strategic goals. If your team is reviewing benchmarking results and asking, “Now what?” – we’d love to talk.
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