Shutdown & Turnaround Optimization

Industry: Mining & Industrial

Client Situation

A large mining and processing operation faced repeated shutdown overruns, unclear scope definition, and poor coordination between maintenance, operations, and contractors.

Challenges

• Shutdown scope was not risk-based
• Job plans lacked detail and accurate duration estimates
• Contractor coordination was inconsistent
• Materials and parts were not staged properly
• Post-shutdown reliability was unpredictable

Approach & Methodology

• Conducted a full shutdown readiness assessment
• Developed a risk-based scope definition process
• Rebuilt job plans with accurate durations and resource requirements
• Implemented a shutdown control room and daily performance tracking
• Improved contractor onboarding and communication protocols
• Established post-shutdown reliability checks

Key Deliverables

• Shutdown readiness checklist
• Detailed job plans and resource loading
• Contractor coordination framework
• Daily shutdown dashboard
• Post-shutdown reliability verification process

Results & Impact

• Shutdown duration reduced by 14%
• Cost overruns eliminated
• Improved schedule compliance
• Higher post-shutdown equipment reliability
• Better coordination between maintenance and operations