Principle 5—Define the Shutdown Maintenance Process
Figure 5.2 Shutdown Maintenance Process
We defined the shutdown maintenance process using the diagram illustrated in Figure 5.2.
The main features of this process are:
• Well ahead of time, management installs a team leader and identifies future team members of all disciplines. Their roles are clearly defined. The premise of the shutdown is clearly established, from which the objectives may be derived.
• Timely compilation of the work list, including a review of process is sues, e.g., catalyst regeneration.
• The team challenges all items in the work list using a risk-based approach. They freeze the revised work list and, thus, the scope.
• Any new work proposed after the freeze has to surmount a tough business hurdle.
• The team identifies contractors at this stage.
• The planner uses a multidiscipline-integrated planning, scheduling, and resource optimization of all work in the scope (people, equipment, cost, etc.). This results in one plan for all disciplines, optimized for all resources. Contractors are fully involved in this work.
• Use of brain-storming exercises to identify alternative solutions for expensive items of work at this stage, e.g., scaffolding rationalization.
• Actual shutdown execution is a seamless and integrated process from the time the feed is cut off until the time finished products start to flow to storage. During this entire period, the team leader is solely in charge and manages daily coordination meetings, daily safety supervisors meeting, completion of inspection before the halfway point, and daily update of plan. The team leader applies a tough business challenge for emergent work.
• Top management including the GM frequently visit the site, show visible support, and get a first-hand "feel".
• The team leader carries out a post-implementation review and feed back (improvement cycle), soon after completion of shutdown.
I published the new maintenance philosophy document, Principle 1 described above, within three weeks of arrival. The remaining four principles, which were based on this principle, followed in the next few weeks.