Executing a Turnaround 54% faster than ever before
A Middle Eastern refinery aimed for a top quartile turnaround, reducing their historical mechanical window from 39 to 18 days, marking a 54% improvement.
Context/Challenge
A Middle Eastern refinery historically struggled to deliver their turnarounds against planned and competitive targets. This time, they aspired for a dramatic improvement, to achieve top quartile performance.
- Our client had never achieved a top quartile turnaround in their history, representing a significant target for the organization and its partners.
- The impacts of a global pandemic were still adversely affecting the supply chain and applying constraints to possible ways of working.
- The organization had to build the governance to manage and communicate an aggressive schedule to ensure environmental and safety compliance.
Approach
We were engaged to increase the likelihood of the safe execution of a major turnaround within a planned execution duration window.
We accomplished this through our Turnaround Excellence program (TARx), where we focused first on planning – helping build the strongest possible plan and schedule, which was clear in scope, adequately planned, and aligned with contractors, then execution – helping ensure readiness to execute, then boosting efficiency while minimizing risk.
Throughout the program, we focused on essential aspects for high performance and good team engagement:
- Planning and Collaboration: Clear and controlled scope, integrated critical schedules, aligned stakeholders, and high collaboration.
- Optimization and Risk Mitigation: Extracted opportunities for savings, reduced schedule duration, and mitigated risks through data-driven prioritization.
- Safety and Execution: Ensured safe execution within cost and schedule targets, reinforcing safety guidelines, planned work durations, and managing simultaneous operations effectively.
During execution, we focused on:
- Emphasized Readiness: Brought visibility towards readiness to execute, and during the countdown to start, enabled high collaboration between operations, maintenance and contractor teams.
- High-Quality Governance and Communication: Designed a framework for consistent communication, maintaining momentum and focus on critical actions.
- Real-Time Lessons Learned: Actively captured real-time lessons, enabling quick and timely improvements, while logging areas for systematic improvement.
Result
- 5.7 days of Event Schedule Optimization
- USD$ 42mm in added production value
This client celebrated after achieving a top-quartile turnaround result, dramatically improving their performance over historical trends. This turnaround exceeded our client’s expectations with a 5.7-day schedule improvement on their already ambitious target. Throughout the engagement, we coached leaders on best practices and helping them improve their internal practices for sustainability.
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