Live Schedule is Changing The Turnaround Game
“Advanced C2stat solutions bring visibility to all stakeholders driving improvements in communication and team collaboration”
–Source: CP Chem TA Project Controls Manager
Turnaround Industry Challenges
- Printed schedules are out-of-date as soon as they are printed – contains yesterday’s status
- Impacts decision making from reduced visibility impacting communication and collaboration
- Bow Wave Management
- Systems not used to full capability, not aligned to business needs
- Insufficient time for schedule analysis and recommendations
- Information spread across systems at different layers
- Systems hard to use
- Limited access to certain users
- High degree of training required
- Difficult to search and update
- No single ‘source of truth’
- Reports are not Dynamic
- Integrate Site Procedures?
Introduction
These STO events are an ideal place to look for cost savings and improvements. They are a substantial contributor to the overall cost structure of any chemical manufacturing facility requiring a significant investment in asset management. Not only do STO events cause the company to lose revenue while it is off-line, but the event project itself is extremely complex, expensive, and risky. They can cost $35 million or more over a 25 to 30-day period and are typically performed every 12-24 months for each plant unit. Each day an STO event goes over its planned schedule can translate in an additional $1 million or more in lost revenue and labor costs based upon the plant unit type of product, production levels, and event scope.
Problem
Turnaround leadership desired to begin the journey of improving execution of CP Chem turnarounds beginning with obtaining timely and accurate field controls status. A proof-of-concept was designed for the Port Arthur STO Event and executed from September 12.
Areas for focus of the proof of concept include:
- Push status updates from the field providing for accurate and timely updates
- Allow stakeholders to access the LIVE schedule at anytime from anywhere
- Monitor critical path and float on activities with LIVE status
- View near real-time Key Performance Indicators
C2stat Solution
The C2stat® (Command and Control visibility immediately) deployment for CP Chem was designed to remove the risk of inefficient work execution by providing a full solution of technology, process, and personnel deployed onsite throughout the execution of the STO event.
C2stat® delivered turnkey execution confidence by providing a single, unified command and control solution with a real-time interactive schedule by utilizing a proven electronic 24-7 data collection process. With this capability, C2stat® enabled optimal communication and coordination across the team from the field, providing the basis for improved decision making.
The Results
AREAS OF IMPROVED PERFORMANCE
The following are key areas of improvement as compared to traditional execution methods.
Collaborative Solution Requirements
Improved cultural assimilation into the CP Chem turnaround team as well as major contractor teams.
Real-Time Trusted Status
Real-time, trusted status update for the activities update by Tactexs was available to everyone from anywhere.
Real-time schedule and key performance indicators (KPIs)
KPI’s were available to provide visibility (traditionally only available from the end-of-shift schedule performance and a day behind actuals).
Communication and Collaboration
Improved vertical and horizontal communication were observed driven by real-time schedule visibility.
Scheduling Efficiency and Analysis
Schedulers are no longer burdened with performing all activity updates.
System-Assisted Execution Monitoring
The system performs continuous intelligent monitoring of all jobs and progress.
System-Assisted Notifications
Fast, automated notification of relevant events to STO management, operations, maintenance and other key personnel for decision making are available.
Turnaround Meetings and Turnovers
No longer did teams have to spend significant amounts of time to understand where they were in relation to the schedule but rather what actions are required to improve performance.
