Make the Leap from “Better” to “Best-in-Class”

For those struggling in the bottom and third quartile of turnaround performance, a focus on becoming more predictable through improved planning and preparation is key. But what about those sites that have turnaround predictability under control? How do they make the leap from second quartile to top quartile?

To answer that question, AP-Networks conducted a research program aimed at understanding the practices of best-in-class turnaround performers. The study correlated 21 distinct Turnaround Value Practices (TVPs) with turnaround performance. These TVPs are out-of-the-ordinary practices that drive competitiveness. Although individual practices are often part of a site’s turnaround work process, Industry leaders take the execution of these TVPs to the next level by moving past a simple “checking the box” mentality. By acting on a recommended set of TVPs that will have the biggest impact for the specific event in question, sites can execute the right scope right and make the leap to top quartile.

To determine which TVPs will make the biggest impact at your site, AP-Networks employs a statistical model that accounts for past site performance, challenges and constraints, and upcoming event characteristics to determine a recommended set of TVPs to be implemented.

ROADMAP TO BEST-IN-CLASS

Turnaround Value Practices:

• Out-of-the-ordinary, well-implemented practices that improve the planning, readiness, and performance outcome of a turnaround
• Not just standard tasks; instead, they follow a defined and distinct methodology and must be followed for the entire life cycle of the turnaround
• Require relevant stakeholder involvement to ensure alignment
• Identified ideally during Phase 1 or at Phase 7
• Outcomes and results are formally documented, and actions are tracked to completion

TVPs and Objectives

Effective Site Leadership: Orient leadership with best practices for steering an event.

Premise Setting: Establish a premise that aligns stakeholders across the organization.

Risk Identification and Management: Identify, evaluate, quantify, and prioritize risks; develop mitigation plans for high impact – high probability risks.

Resource Planning: Provide a comprehensive resource plan to deliver optimal turnaround preparations for one or multiple turnarounds at a single site.

Event Alignment and Integration: Align the organization on the development of effective planning and preparation strategies for project and maintenance scope integration.

Scope Index Benchmarking: Optimize maintenance scope and establish reasonably competitive targets.

Contract Strategy: Design an event-specific contract strategy, contracting plan, payment plan, and associated timeline.

Decontamination Strategy: Maximize the likelihood of a safe and predictable handover during process unit decontamination.

Risk Based Scope Review: : Optimize the turnaround scope through a rigorous and quantified challenge process.

Organizational Alignment: Improve the alignment within the site and/or project/turnaround organization.

Process and Behavioral Safety: Assess whether all procedures, systems, and mechanisms are in place for an event-free turnaround.

Planning and Controls Framework: Assess and map all work practices and tools used during preparation and execution, and analyze how data transfer between different tools will be managed.

Schedule Development and Management: Develop the premises and basis for a fully integrated schedule that effectively supports Execution Coordination and Progress Management.

Operations Readiness: Assess operations planning and deliverables with a focus on operations status, team dynamics, and the deliverables that are most critical to event success.

Cost Estimate and Controls: Ensure that the team is positioned to a) set a realistic and achievable cost estimate with appropriate levels of contingency and b) provide accurate and timely tracking, reporting, and forecasting during execution.

Schedule Optimization: Review the integrated schedule to validate the use of codes and structures, network logic, the schedule control network, calendars, and user-defined fields.

Transitioning to Execution: Transform the turnaround preparation team into the turnaround execution team.

Execution Efficiency Program: Improve productivity and effectiveness during pre-turnaround and turnaround execution.

Lessons Learned Identification and Implementation: Capture turnaround successes and improvement opportunities in a structured manner with a resolved implementation plan.

80/20 Scope Identification and Definition: Develop future site turnaround scope.

Cost Forensic Analysis: Investigate the turnaround performance data, identify areas for potential improvements, and develop action plans to realize cost savings for future turnarounds.