Planning and preparing shutdowns from within Production

In these dynamic times, more and more is asked of production, which has its effect on the entire organisation. As a maintenance organisation, anticipating production is the result of good work preparation and planning. The pressure from the market, among others, is high and requires maximum commitment and availability of installations. Communication and coordination within the individual departments (Production, Maintenance, Projects and SHEQ) has become even more important. The integration of these departments in the preparation of maintenance stops is therefore essential.

Companies often still use a traditional approach to planning and work preparation for shutdowns, turnarounds, outages and pit stops. A lot of effort, time and money is repeatedly spent on the preparation of these maintenance stops. The outcome of the work preparation has a direct impact on the production planning in terms of availability of installations, systems, etc., as well as the deployment of personnel. Maintenance stops are an extension of maintenance, inspection and cleaning work, or modifications and/or renovations. Often - in about 70% of the cases - it concerns preventive maintenance.

Planning and work preparation from the perspective of Production works differently: all activities that may affect a process unit, equipment, production or energy system need to be transparent. The aim is minimal or no downtime of these process units, equipment, production or energy systems, so that the sequence of decommissioning and commissioning is leading in planning and work preparation. In order to achieve this transparency, use is made of the SBS (System Breakdown Structure) in addition to the traditional WBS (Work Breakdown Structure).

Maintenance stops regularly demand the utmost from a production and maintenance organisation: small shutdowns mainly due to their relatively high frequency, large turnarounds due to their complexity. In both situations, the preparation is aimed at completing the maintenance stop with the right quality, safely, on time and within budget. The plant can then be quickly put back into operation. But to realise this, it is crucial that planning and work preparation are carried out accurately. Because in many organisations, the competencies to put this into practice are gradually disappearing...

This course offers a first or renewed acquaintance with planning and work preparation for maintenance stops. The perspective chosen is that of Production, which has an interest in a smooth turnaround with minimal downtime. The emphasis is more on shorter maintenance stops in discrete manufacturing (run-to-run stops) and less on extensive turnarounds in the process industry. The organisation of an optimal integral work preparation, planning and optimal coordination of planning activities with impact on availability of production systems, equipment, safety, etc. are dealt with in the course. The course offers practical tools for those who (for the first time) have to play a role as planner or work preparer in shutdowns, turnarounds, outages or pit stops.

The following topics are covered during training:

• Philosophy of work preparation and planning
• Organisation of work preparation and planning
• Standardisation and simplification
• Application: planning software (MS-Project)
• During this training you learn:

Planning from within Production:

• A new approach to the preparation of maintenance stops
• New insights in the approach of work preparations
• New insights in the approach and setting up of a planning
• The application and creation of an integral schedule
• Simplifying work preparations (Lean approach)
• The application of standards
• The application of breakdowns
• Optimal tuning, successful cooperation
• Working with a plan map

Day 1: Integral approach to stop events

• Philosophy of a stop event
• Production planning and scheduling
• How is your organisation set up?
• Standardisation of work processes
• Work preparation vs. planning
• Integrated work planning
• Integrated planning, the standard
• How do I set up a planning?
• Impact of energy/process systems

Day 2: Impact to availability of installations

• Practical experience: guest lecturer from Janssen Pharmaceutica (Davy Bens)
• Optimal application of breakdowns (WBS, SBS, OBS and CBS)
• Working out an assignment (plan map)
• Where does the focus lie within planning?
• Dealing with scope changes
• Assignment for return day 3

Day 3: Digital preparation

• Working out the assignment
• Using tools
• Applying planning software (MS-Project)
• Working lean with SMED
• Using dashboards
• How do we get our planning and preparation done in time?
• Evaluation moment

During the training, the link to practice is made in various ways through the input of assignments and a guest lecturer. For example, you will be given examples of companies where things have gone wrong in the preparation and planning, and you will learn how to cooperate successfully and draw up a plan during exercises.