Shutdown Optimization

Live, Virtual, Interactive Workshop

Half of all plant shutdowns are delayed by more than 20%, and 80% go over budget by more than 10%

 

Shutdown Planning and Turnaround Management Workshop

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Introduction:

This Effective Shutdown Planning and Turnaround Management workshop will walk you through key concepts and strategies to manage effective plant shutdowns and turnarounds. Individuals or teams will learn how to create a shutdown and turnaround roadmap and a clear assurance process plan, aligned with your organization’s key business objectives. Thorough understanding of the full equipment life cycle, you will be able to identify gaps in your preparation and execution and plan safe and productive turnarounds, with optimized scheduling and cost control that enable you to deliver both on time and on budget. Additionally, you will also learn to drive and navigate your shutdown, turnaround & outage events by using DSM (Dynamic Scheduling Methodology) and Primavera™ P6 tools.

Objective:

The course objective is to optimize and reduce the total cost of planned outages while maintaining and improving unplanned plant availability.

As mentioned above, half of all plant shutdowns are delayed by more than 20% and 80% go over budget by more than 10%. Frequently, the work scope increases unexpectedly by up to 50%. In industries that operate 24/7, where downtime can cost $100,000 per hour or more, these expensive, time-consuming projects must be treated like pit stops, with maximum preparation and minimal surprises. This requires a profound understanding of the critical elements, drivers, and constraints that shape the event.

With the guidance of global STO subject-matter expert, E. J. Lister, you will walk through in an interactive platform, the key concepts and strategies to manage effective plant shutdowns and turnarounds. You will learn how to create a shutdown and turnaround roadmap and a clear assurance process plan, aligned with your organization’s key business objectives. With an understanding of the full equipment life cycle, you will be able to identify gaps in your preparation and execution and plan safe and productive turnarounds. Then, with optimized scheduling and cost control, you will be able to deliver both on-time and on-budget events. Additionally, you will also learn to drive and navigate your shutdown, turnaround & outage events by using DSM (Dynamic Scheduling Methodology) and Primavera™ P6 tools.

Content:

Module 1 – Asset Management (Workscope & Budget Optimization)

In this session, participants will learn to establish the most optimized Scope of Work & Budget for their event using RBSR (Risk-based Scope Review) methodology and budgeting tools. The goal here is to focus on effectiveness and the 2 key indicators of Cost and Schedule Duration (timeline with minimal production loss). Participants will learn to:

  • Establish a 5- 10- 15-year STOp Plan for Sustainable & Profitable Operation
  • ERP/CMMS Data Management with Industrial Digitalization and Data Management
  • RBSR (Risk-based Scope Review)
  • Establishing a 3-Phase Budget
  • Establish STO Event Kick-off
  • Establish Goals & Objectives
  • Establish realistic KPI (Key Performance Indicators) & Targets
  • Establish Vision & Mission
  • Establish the STO Organization with Roles & Responsibilities
  • Establish WBS (Work Breakdown Structure)

Module 2 – Strategic Planning & Plan2Plan

In this session, participants will learn to facilitate Strategic Planning Workshops as part of the Plan2Plan (Milestone Schedule) from event kick-off to feed-out date (T-minus Zero). Methodology, Navigational Roadmap, and tools will be provided. Participants will learn to collaborate in a transparent manner, using MS Teams© or other digital solutions to ensure everyone contributes to the planning of the event with 3 key indicators in mind: Safety, Quality, Worker Wrench-time Efficiency. Participants will learn to:

  • Establish a Plan2Plan Milestone Schedule
  • Establish RACI Matrix and assign Responsibility and Accountability to key members of the STO Event Team (Steering Committee and Core Team)
  • Create and facilitate Strategic Planning Workshops for: Permitting, Tools & Materials, Planning, Inspection, Procurement/Contracting, HSE, Logistics, Mobilization, Communication & Meetings, Resource Management, Execution Management & Control, QA/QC, Shutdown/Start-up, LOTO, etc.
  • Learn to establish a Weekly Core Team Meeting (create an agenda)
  • Learn to create an Action Tracker (provided)
  • Establish Contract Types based on Work Type with Terms & Conditions
  • Perform a Readiness Assessment (tool provided)
  • Industrial Digitalization for web- and cloud-based transparent, secure and collaborative teams
  • Working remotely

Module 3 – Work Package Planning

In this session, participants will learn the best practices for creating Work Packages, estimating, assembly, and tracking to ensure each package has its contributors involved and adds to the value of the 3 key indicators above. This will include Planning, Estimating, Bill of Materials, Equipment, Drawings, Photos, and preparing to upload to Primavera™ P6 or MS Project©. An example of a Work Package will be provided, along with best-practices, templates, and tools. Participants will learn to:

  • Basis of Planning & Scheduling review (documents)
  • How to establish a Planning Team
  • Roles & Responsibilities of Planning Team
  • Create world-class Work Packages (examples provided)
  • Track Work Package Progress (tool provided)
  • Benchmark estimating standards
  • Understand PF (Productivity Factors) for non-productive time
  • ITP (Inspection & Test Plans)
  • MOC (Management of Change)

Module 4 – DSM (Dynamic Scheduling Methodology)

In this session, participants will learn the art of scheduling in Primavera™ P6 – also applies to MS Project© in order to produce the most optimized Project Plan: Lowest Cost, Shortest Duration, Least Amount of Resources. A manual for P6 will be provided, along with lessons and links to download Oracle P6 and XER lessons. Participants will learn to:

  • DSM (Dynamic Scheduling Methodology) in Primavera™ P6 (examples provided)
  • Schedulers’ Roles & Responsibilities
  • Scheduling techniques and best practices
  • How to produce the most optimized Project Plan: Lowest Cost, Shortest Duration, Least amount of Resource (Direct and Indirect)
  • Create Daily Shift Reports
  • How to Drive your STO Event
  • Receiving accurate and timely field updates

Module 5 – DEC (Dynamic Execution Control)

In this session, participants will learn how to Drive & Navigate their events using War Room Strategic Sessions and Execution Controls. This is the most important, valuable session to be presented. Demonstrations using Primavera ™ P6 and a simulation exercise will be included. Participants will learn to:

  • How to establish the War Room
  • War Room Strategy Sessions, attendance and agenda
  • How to Navigate your STO Event
  • LOTO (Lockout/Tagout) procedures and best practices (tool provided)
  • Density Modeling, Risk Mitigation and Congestion Management
  • Using pf (performance) to measure Wrench-time, Float Burn, Planning Effectiveness, and more
  • Execution Coordinators vs. Field Supervisors
  • Measuring Earned Value vs. Planned and Actual (CPI/SPI) and Project Controls
  • Measuring Wench-time Efficiency
  • How to create a Mission Control Dashboard for Execution Phase
  • Managing Discovery Work and Budget Contingency

Module 6 – Flawless Start-up, PSSR (Pre-start-up Safety Review), Closing & Lessons-learned

In this session, participants will learn about flawless start-ups with PSSR and how to properly close-out their event and use lessons-learned to create their subsequent events, with templates and tools (provided). We’ll also do a review of previous sessions and question and answer period to finish off. Participants will learn to:

  • Flange Management Strategies
  • Using a world-class PSSR (Pre-Start-up Safety Review) process
  • Commissioning & Flawless Start-up
  • Capturing Lessons-learned
  • Closing and critiquing your STO Event
  • Preparing for your next STO Event and review of training, with Q&A

Benefit:

By the end of this program, participants will be able to:

• Demystify the key objectives of shutdown & turnaround to ensure teams align with organizational goals
• Plot out shutdown & turnaround scopes and manage the necessary contracts, materials, and procurement
• Grasp the principles of change management and ensure team safety and productivity throughout the turnaround process
• Control present and future maintenance costs through clear estimation and optimization processes
• Learn to Drive & Navigate your Shutdown and Turnaround event with DEC (Dynamic Execution Control) and a War Room concept to finish early and under budget (high earn/low burn)


Who should attend?

The Effective Shutdown Planning and Turnaround Management workshop is suitable for professionals that are involved in the planning, co-operation, and execution of plant shutdowns and turnarounds. This includes practitioners who are Senior Managers, Managers, Engineers, Supervisors, and Coordinators that are in charge of:

• Project
• Plant Managers
• Asset Management
• Procurement
• Shutdown or Turnaround Planner
• Planners & Schedulers
• Operations Shutdown / Outage
• Construction Superintendents
• Inspection & Materials
• Health, Safety & Environment
• Maintenance/Maintenance Planning
• Reliability/Inspection
• Testing and Commission
• Mechanical Engineering
• Electrical Engineering
• Production
• Project Management
• Facilities Management
• Planning, Scheduling and Cost Control


Meet the Instructor

E. J. (Ted) Lister – Chief Navigator, STONavigator

Connect: LinkedIn Twitter: @STONavigator Email: ejlister@stonavigator.ca

EJ (Ted) Lister is a specialist in the field of Asset & Resource Performance in the oil & gas, petrochemical, mining, and energy sectors-specific to Maintenance/Reliability, Shutdowns, Turnarounds, and Outages-with a passion for people and change management. With years of international lessons-learned experience and best-practice knowledge, Ted works to educate stakeholders on Effective Shutdown Planning and Turnaround Management through a series of lessons on best-practice methodologies, supported by digitalization and technology, with a keen interest in establishing a collaborative work environment through digitalization of business processes to reduce risk, cost and production losses. For the past 30 years, he’s traveled to more than 40 counties on 5 continents, instructing, mentoring, and consulting to top Organizations, helping to improve employee and contractor competencies, enhance production, reduce risk, and save millions in operating expenses for multi-national companies.

Ted is the creator of several best-practice methodologies and the author of publications and materials for driving business performance. Ted’s latest book, Lead, Manage or Dig (cultivating an HpO) is a culmination of his brilliant thinking. Ted is as comfortable and confident in the boardroom as he is in the lunchroom and the shop floor—his background is in the field of Electrical/Instrumentation with accredited Project Management and HR skills—which he attributes to his success as a business performance/operational excellence consultant. Ted’s presentation and speaking style are inspirational, educational, and entertaining.


Workshop Pricing & Details:

Tell us you’re interested in saving money by optimizing your shutdowns and turnarounds send us an email.

Please call our office for information: (917) 554-3444


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