When it comes to planning and executing a successful plant shutdown, it’s all about learning from previous shutdown work and making improvements. And we all know the saying “If you can’t measure it, you can’t improve it”. That’s why it’s imperative to measure a standard set of metrics on every one of your major plant shutdowns. Here are 30+ key metrics for your plant shutdown.

Evaluation Phase of Shutdown Maintenance

The Shutdown Evaluation Phase is the final phase of shutdown maintenance. Evaluation involves steps to use a process of assessment and continual improvement to ensure that any future shutdown and turnaround plan can be improved. It is of vital importance that a post-shutdown analysis is carried out soon after the completion of the shutdown.

Part of the evaluation phase is collecting vital statistics of the plant shutdown. How did we perform against the plan? How did we perform against budget? How did this shutdown compare to previous shutdowns?

When you tabulate these key metrics on a spreadsheet, with a separate column for each individual plant shutdown, you are likely to see specific trends developing. It is important to take notice of these trends and to act on them in an appropriate manner.

5 phases of shutdown maintenance

30+ Key Shutdown Metrics

Here are the shutdown metrics. You may also like to include safety metrics like:

  • Lost Time Injuries
  • First Aid Treatments
  • Hazards
  • Incidents etc.

Note that the Final Shutdown Schedule, also referred to as the baseline, is the schedule approved for execution by management and used as the plant shutdown schedule.

Planned shutdown tool-time duration The tool-time duration which has been budgeted for, has been agreed with the Production Department and was shown on the final shutdown schedule.

Actual shutdown tool-time duration – The actual tool time for the shutdown. Detail of shutdown overrun times and causes should also be recorded.

Shutdown Percent Complete Metrics

Quantity of planned work (work orders) – The number of planned work orders on the Final Shutdown Schedule.

Quantity of planned work (man-hours) – The quantity of planned man-hours on the Final Shutdown Schedule.

Quantity of planned work completed (work orders) – The number of planned work orders on Final Shutdown Schedule which were completed during the shutdown.

Quantity of planned work completed (hours) – The quantity of man-hours on Final Shutdown Schedule planned work orders which were completed during the shutdown.

Quantity of planned work completed (%) – Planned work orders completed / Planned work orders

Quantity of planned work cancelled (Work Orders) – The number of planned work orders on Final Shutdown Schedule which were cancelled. Reasons, why they were cancelled, should be well documented.

Quantity of planned work cancelled (hours) – The quantity of man-hours on planned work orders on Final Shutdown Schedule which was cancelled. 

Quantity of planned work cancelled (%) – Cancelled planned work orders / Planned work orders

Quantity of planned work not completed (work orders) – The number of planned work orders on Final Shutdown Schedule which was not completed (excluding cancelled work orders). Reasons, why they were not completed, should be well documented.

Quantity of planned work not completed (man-hours) – The quantity of man-hours on planned work orders on Final Shutdown Schedule which was not completed (excluding cancelled work orders).

Quantity of planned work not completed (%) – Cancelled planned work orders / Planned work orders

The number of contractors – Count of all contractors engaged for shutdown execution. The number per contracting company should also be well documented.

Quantity of unplanned/emergent work completed (work orders) – The quantity of unplanned/emergent work orders completed during the shutdown.

Quantity of planned work completed (hours) – The quantity of man-hours on unplanned/emergent work orders completed during the shutdown.

Quantity of planned work completed (%) – Unplanned/emergent work orders completed / Planned work orders

Shutdown Costs

Total budgeted cost – The approved shutdown budget, including labour, materials and logistics.

Total planned cost – The planned cost for the shutdown, including labour, materials and logistics.

Total actual cost – The actual cost for the shutdown, including labour, materials and logistics.

Labour planned cost – The planned labour cost for the shutdown.

Labour actual cost – The actual labour cost for the shutdown.

Materials planned cost – The planned materials cost for the shutdown.

Materials actual cost – The actual materials cost for the shutdown.

Logistics planned cost – The planned logistics cost for the shutdown. This may include things like freight, airfares, travel etc.

Logistics actual cost – The actual logistics cost for the shutdown.

Emergent work actual cost – The cost of emergent work for the shutdown.

Using the CMMS to Compile a Shutdown Report

Most of the shutdown metric data should be able to be extracted from the Computerised Maintenance Management System by the Shutdown Planning team, normally by the shutdown planner. It is important to have a documented procedure on how to extract each metric. This ensures consistency between different shutdowns and shutdown planners.

Planning for Continuous Improvement

One of the keys to the evaluation phase of the scheduled shutdown process is to record accurate information for future analysis and evaluation. These key metrics for scheduled shutdowns form a vital part of the evaluation and help to set up future shutdown and shutdown management for success.