Industrial Turnaround

5 Ways To Optimize Your Turnaround

Reduce labor requirements by 50% and execute an uninterrupted turnaround using a 9-step process that ensures you’re never facing delays or unexpected costs.

The “Turnaround Optimizer Process” is a process that anticipates all found work through detailed planning while getting clear on exact skillsets required so that crews are optimized across your project.

This reduces the number of bodies you need to get the job done, usually by around 50%.

The process focuses on understanding your facility and all potential found work so that all equipment and skillsets are on site, ready to go when needed.

Here are 5 ways the Turnaround Optimizer Process will remove delays, save you money on labor, and ensure the project sees completion on time and with zero injuries.

1. Lean Crews

Most contractors have no issue gathering as many as 60 or more people to make sure you have everything you need to get the job done. Of course, there still hasn’t been much planning around found work, but they’ve sent a ton of bodies so they hope they have their bases covered. This approach does not drive cost efficiency.

By understanding your facility and what needs to be done, we can send crews who are cross-trained in multiple skillsets that can handle each task. This way, you have exactly what you need, and not more than necessary.

We’ve found that this process reduces crew size by up to 50%(sometimes more). Those are crew that don’t need accommodations, and are crew that aren’t standing around in the lunch room, getting paid for waiting until other work is completed.

2. Found Work

Found work can break a turnaround.  The best way to get ahead of these issues is to “plan for the unplanned” at the beginning. This means we work together early on to identify where found work is likely. We also bring extra parts and equipment so that anything unexpected doesn’t become a snag.

This ensures that you’re not spending tens or hundreds of thousands, on top of lost production from additional shut down time, getting the parts or equipment you need. By planning these details, you won’t face a critical delay in the middle of the project.

3. Real Time Reporting

Most specialty contractors don’t have consistent, daily data that is easily shared with facility managers so that they know exactly how the project is running. This is because they’re still working with paper.

This becomes a mountain of paperwork that project administrators must try to pull insight from.

Our entire system is digital. When you sign for what has been performed each period, it’s instantly priced out against the contract. You’re given cost reports and dashboards in real time.

You’re also getting updates on productivity, and will always know what tasks are being completed and where they stand against the schedule.

4. Zero Injuries

Our safety process is also digitized, giving you daily safety reports that you can easily access. Employees participate in the safety program and you will always know what the potential safety risks are during the project.

This daily reporting generates safety data that can be actioned and means any identified hazards are dealt with before they have a chance to become incidents.

This exact system drives safety consciousness and is why we’re currently headed into our 9th year with a TRIR of zero.

5. What Success Really Looks Like

It’s not enough to know what you want a completed project to look like. The obvious answer will always be, make the necessary repairs and restore to service. But what we’ve found is that by asking a bigger question, we gain clarity on what you’re really looking for.

And that question is, “If we were 3 months passed the completion of your turnaround, what would have to be true in order for you to be happy?”

We begin with the end in mind which helps us get crystal clear on your expectations. Then we can guide the project by the vision of success you have and want to see become a reality.

This has seen much more success then just sending you a ton of bodies and doing the minimum to get the job done.

Planning Ensures Success

The Turnaround Optimizer Process tackles turnarounds differently by focusing more time on planning, leading to more successful execution.

The extra time spent at the beginning to truly understand your facility is going to cut costs, ensure you stay within your deadlines, and will help keep workers safe.

This preparation and understanding means you’ll have confidence in knowing the status of the project at all times. This confidence is felt across the project and will result in increased productivity and higher safety awareness.

If reducing the bodies you need to get the job done by half while achieving zero injuries and being fully prepared for all found work sounds like the way you’d like to operate your next turnaround, download “The Turnaround Optimizer Process” for free.

It’s an easy, no-fluff read that will share with you exactly how you can lean out your turnaround, save money and drive efficiency while doubling down on safety.

Grab it here.