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Course Outline

  Case studies evaluated

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The following case studies provide the backdrop to the material covered in this course, chosen for the significant impact these types of shutdown have on overall business operations:

  • Copper smelter rebrick shutdown
  • Longwall change-outs
  • Cement plant shutdowns
  • Major mobile machines services
  • Aircraft services
  • Mobile Equipment Shuts
  • Coal and gas power station shutdowns
  • Food processing and brewery shutdowns
  • Coal terminal machine services
  • Mining Fixed Plant Shutdowns

Shutdown management – planning the work


Shutdown management – an introduction

  • Why do we have shutdowns?
  • A quick tour – industries and how they apply shutdowns
  • Key success factors for shutdown management
  • Shutdowns risk management
  • Align shutdowns with business objectives

Structuring shutdowns for best impact

  • Shutdowns – a maintenance requirement or a production requirement?
  • Shutdown configurations and forward planning
  • Risk Based Maintenance’s contribution to the shutdown scope of work
  • Productivity impact and justifying shutdowns
  • Maintenance’s impact on availability and how it affects shutdowns

Project management applied to shutdowns

  • Project management tools, systems and methodology applications
  • The ideal project management framework, does it exist?

Review of software & systems applications and how to best apply them

  • Scheduling tools and its application
  • Computerised maintenance management systems
  • Shutdown control tools – what is out there?

Scope of work determination

  • What goes in and what stays out of the scope of work
  • Managing scope creep and emerging work
  • Obtaining commitment through participation

Shutdown management – working the plan


Work package design

  • Work packages or work orders?
  • Defining realistic and effective work package templates
  • Application of CMMS supporting Shuts
  • Documenting the scope of work and control work package development
  • Budgeting and resourcing of shutdown activities
  • Job safety and environmental analysis

Shutdown schedule development insights

  • How important is the Project Schedule?
  • Structuring the schedule configurations
  • Loading work packages and defining activity dependencies
  • Optimising the schedule – what is important?

Shutdown readiness

  • On your marks, get ready…
  • Assessing your readiness and getting it right
  • Common mistakes and how to learn from them

Resources and logistics management

  • Labour resources smoothing – employees and contractors
  • Spares and materials
  • Equipment, tools and facilities
  • Information
  • Time!

Optimal work execution control during the shutdown

  • Concept of diminishing influence as project progresses
  • Real time, visual work flow management structures and tools
  • Methodologies/mechanisms to reduce Shut durations
  • Information administration
  • Communication management
  • Handover practices for shift based work
  • Safe working, quality delivery
  • Progress reporting
  • Cost control

Master planning for shutdowns

  • Conducting the Post Project Review – what is the purpose?
  • Master shutdown management models
  • Asset Management Plans as mechanism to support Shutdown Management
  • Continuous improvement – seamless from one shut to the next
  • Assessment of appropriate shutdown practices

Creating an action plan to take back to works


This session will focus on developing a summary of the key takeaways everyone has from this program, including action planning and points to remember. The instructor will collate this, print it up and email to all participants.

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