Optimization of Shutdown and Start-up Phases
Integration and Optimisation of Event Schedule
Improvement of Productivity in Execution

Improving Turnaround Predictability

A European refinery aimed to deliver a predictable mega-complexity turnaround and succeeded in reducing their unplanned production losses by $30MM.

“Working with RLG is a different experience to other consultancies – I can see the work that they are doing to support my team and me personally, rather than adding more work to us”

— Lead Scheduler

Context/Challenge

A European refinery had a recent history of significant turnaround schedule overruns and unplanned production losses, despite aiming for the lower end of Solomon second quartile. To achieve their target of upper second quartile performance, they identified three key areas of improvement:

  • Operations Optimisation: Delivering the shutdown, decontamination, and start-up of the refinery in a safe and predictable way.
  • Schedule Optimisation:  Integrated project and maintenance schedules, reduced critical path durations, understanding and mitigation of schedule risk.
  • Productivity in Execution: Create an effective execution Operating Rhythm for the front-line teams and coach key leaders for productivity improvement.

Approach

We were engaged to work within the existing structures and teams within our client organisation, with two guiding principles:

  • Avoid increasing the workload of the team: work towards our own measurable results and own our deliverables.
  • Make it sustainable: Partner with the team in a way that would allow our implementation to become part of their ways of working in future TAs.

Two Implementation Coaches used RLG’s Turnaround Excellence Framework (TARx) to support our client’s focus areas:

  • Operations Optimisation: An intensive series of Schedule Quality Reviews (SQRs) optimised durations and reduced the schedule risk for shutdown, decontamination and start-up. These workshops prioritised those units which were critical or near critical path, had a high schedule risk or uncertainty, or which would undergo chemical cleaning for the first time.
  • Schedule Optimisation: Improved visibility through an integrated capital project and maintenance schedule, helping avoid an unmanageable workload for the scheduling team immediately before their key delivery milestone. Facilitated a series of SQRs to optimise the critical path in each production line and to align the execution teams around a predictable schedule.
  • Productivity in Execution: Our team worked with the execution leads to establish an effective Operating Rhythm. This ensured that the right information was available throughout their organisation at the right time. In addition, we worked closely with our client’s Operational Excellence team to build their coaching skills to effectively pass on productivity recommendations in execution.

Result

  • Overrun of the event schedule reduced by 11.5 days
  • Production losses reduced by $30MM
  • Repeatable processes and skills embedded

These results represent a step-change improvement in this site’s turnaround performance, and an important building block in our client’s continuous improvement journey.

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