Shutdown Turnaround and Outage Competency Improvement Program

1. 1© Life Cycle Institute© Life Cycle Institute Shutdown, Turnaround and Outage Competency Improvement Program Developed by Joel Levitt and the Life Cycle Institute

2. 2© Life Cycle Institute Clients who have implemented Shutdown, Turnaround and Outage (STO) best practices have seen these benefits: • 20% shorter downtime • 40% decrease in start-up time • Achieving stable output days sooner • Less waste • Greater utilization of resources • Fewer instances of improvisation • Increased yield • Uncompromised quality, safety and compliance • Cost savings on labor, materials and rentals

3. 3© Life Cycle Institute A three-week best practices program developed by Joel Levitt and the Life Cycle Institute  • Assessment of current processes and procedures • Workshop: Leadership for Shutdowns, Turnarounds and Outages  • Workshop: Planning for Shutdowns, Turnarounds and Outages • Individual coaching on STO planning  • Re-assessment of how practices have been applied

4. 4© Life Cycle Institute Week 1 • Assess the organization’s current shutdown processes and procedures • Set goals based on gaps identified in assessment • Guide development of processes and procedures to reflect best practices • Deliver 2-day Leadership for Shutdowns Turnarounds and Outages workshop

5. 5© Life Cycle Institute In the Leadership for Shutdowns, Turnarounds and Outages workshop, participants will learn how to: Assess their leadership and decision-making style Motivate teams and sustain morale during a planned outage Cope with difficult situations and people Practice verbal and non-verbal communication techniques Handle the legal side of a shutdown Develop a personal action plan to increase productivity Week 1

6. 6© Life Cycle Institute Leadership for Shutdowns, Turnarounds and Outages 2-day workshop 1.4 Continuing Education Units (CEUs) Private Workshops may be tailored to your specific needs and delivered at your site. STO Competency Improvement Program This course is delivered as part of the three-week STO Competency Improvement Program Week 1

7. 7© Life Cycle Institute Who Should Attend • Maintenance Managers • Maintenance Supervisors • Key Staffers in Heavy Maintenance Environments, • Shutdown/Outage Team Members such as – Maintenance Engineers – Planners – Project Managers – Outage Planners – Project Engineers • Non-Maintenance Managers responsible for shutdowns • Site Personnel with potential to lead and manage future outages Week 1

8. 8© Life Cycle Institute Shutdown leadership rests on three legs PEOPLE SKILLSMANAGEMENT SKILLS TECHNICAL SKILLS Week 1

9. 9© Life Cycle Institute Motivational Techniques Recognition Treat people with respect Offer Training Give them power or ownership Week 1

10. 10© Life Cycle Institute Leading shutdowns requires effective communications Communicate to support management objectives Watch body language - 70% of communication comes from non-verbal cues Be mindful of differences in communication across genders, cultures, ethnicities, and class Week 1

11. 11© Life Cycle Institute What is a contract? When are contracts needed? Types of contracts Rules of contracts Making contract revisions Request bids To handle the legal side of shutdowns, leadership must know… 99 1 Week 1

12. 12© Life Cycle Institute Week 2 • Deliver 3-day Planning for Shutdowns, Turnarounds and Outages workshop • Individual coaching on STO • Set goals based on gaps identified in Week 1 assessment

13. 13© Life Cycle Institute Participants will learn how to: Evaluate the effectiveness of your shutdown effort Measure shutdown efficiency Formulate good contractor relations Unearth tools and technologies to create a backbone for effective plant maintenance and reliability Reduce unnecessary costs Develop a checklist of everything to consider before the shutdown Week 2

14. 14© Life Cycle Institute Planning for Shutdowns, Turnarounds and Outages 3-day workshop 2.1 Continuing Education Units (CEUs) Public Open enrollment Private Workshops may be tailored to your specific needs and delivered at your site. STO Competency Improvement Program This course is delivered as part of the three-week STO Competency Improvement Program Week 2

15. 15© Life Cycle Institute Who Should Attend • Maintenance Planner/Schedulers • Production Supervisors • Storeroom Managers • Maintenance Managers and Supervisors • Operation Coordinators • Plant Engineers • Outage Coordinators • Reliability Engineers • Facilities Managers • Project Managers • Asset Management Specialists • Quality Assurance • Procurement Week 2

16. 16© Life Cycle Institute Many project areas are impacted by shutdown size education@LCE.com Money spent Duration Lead time Project software Contractors Team organization Week 2

17. 17© Life Cycle Institute Target waste during a shutdown One idea can save thousands of $ in waste Lean is war against waste and part of your lean maintenance effort Find the easiest waste and eliminate it Week 2

18. 18© Life Cycle Institute Scoping the Shutdown Look for work Assess condition Validate work Prioritize work Plan work Week 2

19. 19© Life Cycle Institute Shutdown Manager Must be Vigilant for Risk Consequences • Risk to duration of the shutdown • Risk to cost of the shutdown • Risk to quality of product after start-up • Risk to the workers, the public or the environment Week 2

20. 20© Life Cycle Institute Week 3 • Coaching on how to apply the tools and techniques learned Week 1 and Week 2 • Guidance on embedding these best practices into the organization’s culture • Goal progress assessment, accountability and encouragement

21. 21© Life Cycle Institute The Life Cycle Institute uses 3A Learning® to build competency Align ApplyAssimilate RESULTS Establishing clear alignment on expectations Delivering active classroom learning experiences Hands-on coaching to embed best practices into culture

22. 22© Life Cycle Institute 3 Reasons to Choose the Life Cycle Institute Building competency is what we DO! Our team of learning professionals understands what it takes before, during and after training to change behavior to produce results! LCI instructors are trained learning facilitators Rigorous facilitator qualification and certification process Focus on the learning process and transfer to the job Engage learners, reinforce relevancy and integrate prior experience LCI training is an active experience Learning by doing vs. lecture Group activities, assessments, case studies Network with peers Develop action plans to drive results post-training   

23. 23© Life Cycle Institute Education@LCE.com www.LCE.com 800-556-9589 The Life Cycle Institute is the learning, leadership and change management practice at Life Cycle Engineering.