Introduction:
Shutdown and Turnaround management is a key function in all industry setups. Systematic and planned power shutdowns not only save equipment but also enhance their life. Planning and managing power shutdowns, power outages and turnarounds are a complex and highly demanding function in a factory or office environment. About turnarounds, if not properly planned, controlled or managed companies would face budget or cost overruns and delays in schedule, which would have negative impacts on customers. The engineering industry around the world is ploughed with several incidents of poorly managed shutdowns resulting in massive cost overruns and difficulties in resource planning.
Course Objectives:
By the end of the course, participants will be able to:
- Position shutdowns and turnarounds as part of an overall strategy of improving business performance
- Build the best shutdown and turnaround team possible from the resources available
- Reduce the cost and downtime associated with shutdowns and turnarounds whilst simultaneously improving safety performance
- Understand the critical processes, skills and tools required to establish outstanding shutdown performance
- Use our best-in-class Model of Excellence to analyze their own performance, explain key principles to others and build a detailed methodology tailored to their own needs
- Maximize the benefits of planning and preparation through our proactive challenge planning process
- Build a turnaround from the ground up: From concept to execution and review
Who Should Attend?
Turnaround managers, planners, schedulers, reliability engineers, maintenance managers, maintenance supervisors, project managers, project engineers, operations managers, shift managers, operations supervisors and people who are in training for these positions. This course is also designed for contractors who want to contribute to the shutdown performance of clients.
Course Outlines:
Setting shutdowns in context
- The impact of shutdown performance on a business
- Where people tend to go wrong
- How shutdowns fit with asset and maintenance strategies
- The impact of shutdowns on safety, availability and costs
- Where does best practice come from
The unique complexity and risks of shutdowns
- How turnarounds differ from construction and maintenance work
- The conflict of an inherent bottom up process for scope development
- Complexity
- The interconnectivity of multiple tasks
- Uncertainty
- Unknown tasks
- Unpredicted elements
- Unplanned work
- Unfamiliarity
- Novel tasks
- New personnel
- First time operations
- The resource challenge and assembling the right skills to succeed
A structured Model of Excellence for shutdown management
- Origins of the model of excellence and why it was developed
- A graphic model and the critical elements required for success
- An outline model and exploring the sub elements
- A detailed model, the blueprint for success
- The importance of strategy and the principle of front end loading
- How pace setters have moved to structured work processes
- Processes for safety and quality control
- Defining the right shutdown organization
- Planning and logistics
- Execution and review
- Shutdown economics from forecasting to closure
Developing and controlling a shutdown strategy
- Strategic focus has evolved
- The ultimate business goal
- Reducing the annualized penalty of shutdowns
- The key strategic focus for the modern engineer
- The role of the steering team
- Where steering teams go wrong and how to avoid this
- Human factors
- Communication and creating buy in
- How to develop effective teamwork
- Competency development and how we learn
- Assurance processes for cradle to grave control
Managing risk
- Understanding hazard and risk
- A Methodology for predicting strategic risks
- safety, schedule, and cost
- How to reduce and control risk
- Transforming safety performance
- How to avoid conflict between safety, quality, schedule and cost
The art of planning
- The importance of controlling scope
- How to optimize scope of work
- Developing the worklist and controlling late work
- The basic components of competent planning
- Planning facts and fallacies
- Advanced planning techniques
- Moving to a pit-stop mentality and a breakthrough process in planning
- Pacesetter habits for mobilizing towards the execution phase
- Execution and review
- The basic structure
- Exposing the skeleton of a shutdown
- Achieving the best possible start to an event
- Tracking and driving progress
- Managing logistics
- Control meetings and management systems
- Achieving effective plant hand back
- Alternative methods for the turnaround review
Execution and review
- The basic structure
- Exposing the skeleton of a shutdown
- Achieving the best possible start to an event
- Tracking and driving progress
- Managing logistics
- Control meetings and management systems
- Achieving effective plant hand back
- Alternative methods for the turnaround review