Shutdown Management

Our Expertise

Ensuring shut activities are defined, planned, executed, and closed out in a cost-effective and safe manner is an essential part of optimising asset productivity, and with our functional knowledge and established processes, we can help your organisation to mitigate risk, eliminate waste, reduce cost, and deliver your desired operational outcomes.

Our Value

Facilitation of scope definition, planning, preparation, execution and re-commissioning processes
Minimised cost and delays
Maximised productive hours
Rigor and discipline towards key processes and activities
Elimination of waste to save on costs
Optimised operational outcomes
Structured shut training, coaching and mentoring by experienced people

Recent Projects

Shutdown optimisation

Shutdown optimisation

Scope: Review and optimisation of the main plant shutdown cycle of a leading WA process plant.

Success: review of the operating strategy, maintenance strategy, frequency, and drivers for the current shutdown cycle. Following the review the CMMS master data was aligned to the updated shutdown cycle including all statutory and regulatory tasks.

Value: The organisation was able to drop one shutdown from the year reducing the annual maintenance budget by $590,000 while not effecting the plant availability or reliability.
Locomotive overhaul

Locomotive overhaul

Scope: Improve the locomotive overhaul maintenance management process across three fleets of locomotives to achieve overhaul program compliance. The pre-existing process had limited structure and tools and significant amount of wasted time due to disorganisation, which resulted in the initial overhauls exceeding their planned completion date. The issues encountered included limited ability to measure and track progress, components and materials supply shortages impacted progress, disorganisation in the work area and there was no central management system such as a CMMS was utilised. In addition, an improvement in the execution period of each overhaul was required to achieve overhaul program compliance. The key improvement initiatives were to implement a work management structure, set-up and manage overhauls through the CMMS (SAP) and determine the optimum resource requirements to achieve overhaul program compliance.

Success: A work management structure was developed utilising the overhaul scopes of works for the three fleets of locomotives and uploaded in the CMMS (SAP). To create the structure each scope was dissected into discrete tasks, task durations defined, tasks sequenced and grouped and critical paths mapped. The resource options were defined and analysed to determine the optimum resource allocation vs. execution time. This exercise achieved an improvement in planned base execution time (day shift only) of 20% reduction was achieved. A further 30% reduction for a total reduction of 50% over planned base execution was achieved with resourcing on day and afternoon shift. The work and storage areas were also reviewed and improved, with the installation of new storage racks with component allocations and demarcated staging areas within the workshop.

Value: The improvement of the overhaul maintenance management process delivered a work management structure and tools that enabled the team to effectively plan, schedule and execute the locomotive overhauls within their CMMS (SAP). An improvement was achieved in the ability to measure and track progress, component and material requirements were clearly identified and managed within the CMMS system. The project has provided an organised structure to minimise the wasted previously experienced in managing overhauls. This has realised additional capacity, in particular the frontline leadership team, to perform quality field time.