Shutdown ManagementShutdown Management

Managing a Synergistic Shutdown Team

Presented By:

John Parfett

Shutdown Coordinator

DefinitionDefinition

Synergism:

– The action of two or more substances, organs or organisms to achieve an effect of which each is individually incapable.

– Derived from the Greek word “Sunergos” meaning “working together”.

Who is the “Who is the “TEAMTEAM””

Technical Projects

Business

QA/QC

Maintenance

Procurement / Materials Handling

Operations

Health, Safety &

Environment

Where to Start?Where to Start? Team Building

– Mandate the Team

– Identify Team Member Attributes

– Review Shutdown Drivers

– Develop Mission, Vision, and Goals

Where to Start?Where to Start? Team Building

– Develop Milestone Schedule

– Review Previous Lessons Learned

– Identify Risks and Develop Contingency Plans

Where to Start?Where to Start? Define Roles and Responsibilities

– LACTI Chart• Lead

• Approve

• Consult

• Tasked

• Informed

When to Start?When to Start?

The team should be assembled immediately after the last shutdown is completed.

The required commitment is relevant to the role on the team and the schedule.

The Influence CurveThe Influence Curve

0102030405060708090

100

1000 900 800 700 600 500 400 300 200 100 50

Days Before Shutdown

Succ

ess F

acto

rs

How to StartHow to Start

Orientation– Mission

• Plan and safely execute all activities approved for the shutdown within the cost and time allocated.

– Vision

• Success through planning.

How to StartHow to Start

Orientation– Goals

• Schedule, Cost, HSE, Scope.

– Shutdown Drivers

• Safety, Business, Reliability, Legal.

How to StartHow to Start Training

– Shutdown Methodology.

– Work Package development.

– Scheduling and reporting tool.

– Cost Control.

– Soft Skills.

• Facilitation, Conflict Resolution.

Motivational ToolsMotivational Tools

Monetary– Progression

– Gainshare

Personnel Fulfillment–Sense of achievement and career development.

QualityQuality

The quality of the work is a direct result of the level of planning and the performance of the worker.

Remember that Plan B’s are typically executed with a fraction of the planning time allocated to the original plan.

Value Improvement / Best Value Improvement / Best Practice ToolsPractice Tools

Field Rework Index– Construction Industry Institute

Contractor Selection– Pre-qualification

Preparation Checklist

CII Field Rework IndexCII Field Rework Index

CII Field Rework IndexCII Field Rework Index

Preparation ChecklistPreparation Checklist

SafetySafety

Develop an HSE Plan.– Orientations

– Recognition

– Meetings

– Incident Investigation

– Audits

– Reports

SafetySafety

Incorporate HSE into the work packages.– PPE

– Special Precautions

– MSDS

– Safety Bypass Requirements

Safety KeysSafety Keys

Make it Personnel Empower Supervision Consistent Rules Timely Communication Time - Outs Visibility

New RolesNew Roles

Hands off approach. Big picture focus for each discipline

coordinator. Removing Road Blocks Log Books

Long Hours!Long Hours!

Get the right number of support resources and get them early.

Don’t forget the start-up and close-out. Don’t release support resources too early. Manage the time off leading up to and even

during the shutdown. Include proper support resources in your

budgets.

Skilled LaborSkilled Labor

High Risk!– Typically executing the equivalent of

an annual maintenance budget in 4 - 5 weeks

– Your facility is vulnerable to people you don’t know and may not see again.

Skilled LaborSkilled Labor

Success Factors– Make your facility a place contractors

prefer to work at.– Make them feel part of the picture.– Bring the contractor into the planning

process early.– Scheduling.– Incentives.

Shutdowns Alberta WebsiteShutdowns Alberta Website Provides information and schedules for

industrial shutdowns in Alberta– www.shutdownsalberta.com

Resource and Supplier information– Products, Services, Skills & Trades, Offsite,

and Specialty Equipment Subscriber section

– Detailed trade & services information

Strategies for Maximizing Strategies for Maximizing ProductivityProductivity

Set the Tone– Importance of 1st hour of 1st day!

Remove the Road Blocks– Washrooms, Parking, Brassing, Permitting,

Weather restrictions Timely Communication

– Safety Concerns, Scope Changes– Keep internal conflicts private

Strategies for Maximizing Strategies for Maximizing ProductivityProductivity

Earned Value– Measure it and understand it.

Working Hours– Stager Shifts

– 6 -10’s Scheduling Dayshift Vs. Nightshift

SummarySummary

Get the right representation on the Team.

Team Building Bring the support resources in early. Use Value Improvement / Best Practice

Tools

SummarySummary

Make you’re site a preferred site for contractors.

Make your contractors feel part of the team.

Consider other shutdowns in the province when scheduling.

SummarySummary

Keep in control– Communication and reaction time

Measure productivity Plan, Plan, Plan!