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| Improving shutdown execution
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Context / Scope of project
An alumina refinery was undertaking a series of major maintenance and refurbishment shuts on its boiler units. The initial shuts of the series had significant execution issues resulting in delays, cost overruns and significant revenue loss. PIP was engaged to undertake a structured review of the shut execution.
Client achieved:
- Confirmed and crystallised internal thinking on the need to increase shut team resourcing and provided a framework to build alignment on this issue with senior management
- Gained a structured framework for integrated planning and shutdown management incorporating other site teams and contractors
- Identified the need to create a site-wide approach to shut management methodology and to deploy a common set of systems to support management and decision making.
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What we did:
- Interviewed a range of client and contractor personnel to develop a “brown paper” map of the existing shut process
- Ran structured workshops on the shut process with key personnel from a range of disciplines and areas from within the client and contractor organisations to generate ideas on improvement
- Synthesised ideas to deliver a series of high level recommendations on resourcing, systems and management processes.
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