Shutdown and Turnaround
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Shutdown and Turnaround
Shutdowns and Turnarounds are important aspects of running an operation, particularly in asset intensive and continuous process industries. Improvements is these critical processes focus on enhancing the efficiency and effectiveness of planned maintenance activities and to safely bring the equipment back up within the intended timeframe. Optimization of shutdown and turnaround processes begins with effective planning and ultimately effective work management execution. These processes running swiftly and effectively help to minimize production downtime, increase asset reliability once the equipment is back online, and ensure compliance with safety and regulatory standards.
76% improvement in plant overrun
$9.8M additional gross margin
IX® in Action
Our client, a leading refining, chemical, and biofuels company, had a major issue with poor performance in the shutdown and major turnaround schedules of one of its large chemical processing plants. The shutdown and turnaround planning and execution processes were deficient, which led to consistent overruns in planned downtime. Our client engaged with IE to implement shutdown / turnaround improvement and included some of the following activities:
- Improved and optimized shutdown planning and scheduling process
- Improved wrench time efficiency during shutdowns
- Aligned shutdown / turnaround standard process
- Developed supervision skills through the use of a High Performance Management System on a short interval basis to stay on schedule
- Reduced associated contractor labor costs through more effective planning and execution processes
- Reconfigured organization to support the new processes
- Minimized the risks of safety incidents with better planning and execution
