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EES-SIYAKHA CONFERENCE CENTRE

 


Shutdown and Turnarounds
Equipping you to project manage your turnarounds and shutdowns and deliver on time, first time, on budget and on specification

Earn 3 CPD Credits (CPD ref. SAAMA00279)

FOR A BROCHURE IN PDF ... [ click here ]


Plant shutdown for major maintenance on a periodical basis is not merely an insignificant technical event that is carried out by the maintenance function from time to time. It is in fact an integral part of any company’s business plan, which will directly cause major impacts on the company’s business performance. It is playing a pivotal role in ensuring the equipment reliability, production integrity as well as workers personal safety.
                     
Plant shutdowns for scheduled major maintenance work are the most expensive and time consuming of maintenance projects because of the loss of production and the expense of the turnaround itself. The planning, preparation and execution of a turnaround is a complex undertaking that demands effective strategies and attention to details. It also requires a profound understanding of the critical elements to ensure successful turnarounds as well as the drivers and constraints that shape the event.


Why should you attend this workshop?

Approximately half of all turnarounds fail and frequent shutdowns attract negative publicity and impact share values. When it comes to turnaround situations, there is no second chance and speed, quality and project governance is everything.

This course will equip you to project manage your turnarounds and shutdowns and deliver on time, first time, on budget and on specification. Not attending this course and missing out on unique professional know how can seriously jeopardize your project success.

Who should attend this workshop?

This workshop is intended for plant short term and long term (shutdown) managers, planners, and contractor staff, who are involved in the planning, co-ordination and execution of plant shutdowns. The workshop is especially valuable for shutdown managers and co-coordinators, planning/scheduling and cost control staff, construction supervisors, project engineers and contract administrators. Participation from inspection, materials, safety and maintenance engineering is also encouraged.

  • Shutdown/Turnaround Planners
  • Electrical  Engineers
  • Head of Planning 
  • EMD
  • MMD
  • Maintenance Managers
  • Mine Managers
  • Outage Planners
  • Maintenance Planners/Engineers
  • Production Line Managers
  • Procurement Managers
  • Production Line Supervisors

About your facilitator

Eric Maclear is managing director of Resource Techniques SA (Pty) Ltd. In Johannesburg, South Africa. He is a highly respected management consultant with more than 25 years experience. For the past 15 years he has been running his own consulting and training company. He is a trained and qualified Industrial Engineer having studied both locally and internationally. He holds a B. Eng degree and has completed a number of Business School Programmes.

Eric has had much experience in Asset and Maintenance Management and has a particular interest in Reliability-centred Maintenance and Root Causes Failure Analysis. He has held a number of senior management positions with high profile international companies. He began his consulting career in 1980 with an Australian based management consultancy where he completed a number of assignments in implementing planned maintenance systems. He later worked for a prominent SA consulting firm consulting and training in the full spectrum of plant operations. During his career as a management consultant he has successfully completed many assignments across a broad spectrum of industries, facilitated many training courses, and was keynote speaker at international conventions. He has also written and published numerous papers on Root Cause Failure Analysis. Eric has facilitated training courses in Southern Africa, USA, UK, China and Middle East.

Programme outline

Overview of Shutdowns and Turnaround Management

  • Understanding the importance of managing shutdowns effectively
  • Looking at the basic approaches to shutdowns:
    • Turnkey
    • Loose control
    • Tight control
  • Outlining the differences between approaches
  • Providing you with the ingredients for successful shutdowns
  • Looking at management responsibility
  • Identifying the various phases of shutdowns
    • Identify the work
    • Planning the work
    • Scheduling the work
    • Executing the shutdown
    • Shutdown close-out
  • Differences between projects and shutdowns
  • Classic vs 24/7 

Organizing the Shutdown

  • Understanding the role importance of the shutdown coordinator:
    • Personality traits
    • Roles and responsibilities
  • Shutdown Organisation
    • Options to the shutdown organisation
    • Example: organisation structure for a 24/7 shutdown
  • Quality processes
    • Quality control
    • Quality assurance
    • Quality management small projects
    • Quality management large projects
  • Safety plan
    • Shutdown coordinator
    • Engineers
    • Supervision
    • Workers
  • Issues to be addressed in the plan

Shutdown Work Identification

  • Maintenance shutdown scope
    • Categories of work
    • Issue to consider
    • Defining and limiting scope
  • Pre-shutdown work
  • Sources of shutdown work
  • General shutdown checklist
  • Compiling identified work
    • Works order, purchase orders, permits, etc
    • Final Work List
  • Parts, materials and equipment
  • Master materials list
  • Shutdown constraints – elapsed time, resources, funds
  • Prioritising the work
  • Preliminary estimate
  • Job input cut-off date
  • Assignment responsibilities

Shutdown Planning and Scheduling

  • Planning the plan
    • Goals and objectives:
    • Time
    • Cost
    • Quality
    • Safety
    • The 'hot' spot of projects
    • General conflicts
  • Planning the work
    • Work planning flowchart
    • Convert tasks to work orders
  • Elapsed time and staffing
  • Work packages
  • Roles of operations
  • Precedence networks
    • What is programming
    • Activity sequencing
    • Creating the logic network
    • Plug dates
  • Resource Scheduling
    • Adding activity durations
    • Further considerations e.g. weather
  • Activity parameters – meanings and calculations
    • Early start
    • Early finish
    • Late start
    • Late finish
    • Total float (slack)
    • Free float (slack)
  • The critical path
    • What is it and how is it used?
    • The sub-critical path
    • Negative floats (slack)
  • Bar Charts
    • How derived
    • Example
  • Resource Smoothing
    • Resource budgeting
    • Types of resources
    • Resource Leveling
    • Example of Resource Leveling
    • Setting key events and milestones
  • Shortening the critical path
    • 'Crashing' activities and shutdown
    • Time/cost considerations for critical path shortening
    • Schedule control

The Use of Contractors

  • When are contractors used
  • The advantages and disadvantages of contractors
  • Selection of contractors
  • Creating contractor work packages
  • Types of contracts
    • Fixed price
    • Cost reimbursement
    • Time and material
    • Unit price
  • Contract statement of work
  • The contracting/purchasing process
    • Planning the contract
    • Evaluation criteria
    • Requesting contractor responses
    • Selecting contractors
    • Administering the contract
    • Closing the contract
  • Negotiations
    • What is negotiations
    • The negotiation process
    • Negotiation tactics
  • Contract management
    • Before the event
    • During the event
    • After the event

Shutdown Budgeting and Control

  • What is cost and cost management?
  • Cost management processes
    • Cost estimating
    • Cost budgeting
    • Cost control
  • Cost management plan
  • Creating a shutdown budget
    • Included in the budget
    • Excluded from the budget
  • Project cost control
    • Project costs
    • The 'S' curve
    • Earned value management (EVM)

Managing Logistics in Shutdowns

  • Logistics functions during shutdown
  • Duties of the logistics team
  • Duties of the logistics coordinator
  • Storeroom Management – 24/7 shutdowns
  • Management of long lead time items
    • The process
    • Affect on milestones
    • Expediting

Risk Management

  • Component of risk management
    • Identification
    • Quantification
    • Response
    • Response control
  • Secondary risks
  • Retained risks
  • Contingency plans
    • Unplanned events
    • Unexpected gains
    • The contingency plan

Shutdown Execution

  • Managing the work quality
  • Shutdown Master Schedule
  • Daily work schedule
  • Emergent work
  • Safety during the execution
  • Job status update
  • Controlling the shutdown
  • Role of the shutdown coordinator in 24/7 shutdowns
  • Report shutdown status
  • Why shutdowns fail

Shutdown Close-out

  • Shutdown review meeting
  • Project file
  • Final report
  • Shutdown post mortem
    • Aspects to consider
    • Review and analyse
    • Action plan
    • Next shutdown
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© EES 2004    |    Last updated on : Tuesday, 17 April, 2012 22:21