Since it is not your first shutdown, you have many advantages! You can use KPIs to help influence the team's behavior. Think of what needed improved last time and use a KPI to drive change. It's a little wasteful to make KPIs for an area where you're satisfied and the organization is functioning satisfactorily.
I have tried to drive people to earlier planning and preparation and better use of the CMMS during TARs, so some of my individualized KPIs were:
-number of schedule planning meetings and attendance by operations representatives. Count of completed workorder backlog review with operations area lead and the cognizant planner.
-number and value of stand-alone purchase orders that weren't tied to a work order (a bad habit in my opinion, the lower the better.)
-number and value of material issues that were charged to a work center, not a work order. This was another historical bad habit. We used a capitalization rule to really get people to change their ways using this reason and a KPI to show it...we posted the KPI by the storeroom issue point.
-the percent of expected purchase orders placed before the start date (4 months, 2 months, and 1 month ahead) so the purchasing phase got some attention.
-actual cost vs estimated costs and vs planned costs (i.e. compared to the project manager's early estimate and compared to the planner's final plan cost), divided by material, labor, overtime, work orders, and overhead services.
-I kept a daily running list of other people's complaints so we could talk them over during the critique sessions.
-results of safety work like percent of safety valve test failures, internal vessel inspections, and main electrical inspections. This isn't really a KPI but if something is really wrong, the whole project team needs to know.
-Count of safety observations and improvement recommendations
-Count of near-misses
-Visual completion KPI: the schedule was made in MS project, but plotted on large format paper and put up on the planning room wall. Completed work orders and events were highlighted in brown. You could still read the printing, but it was really clear to everyone when we were making progress. Very satisfying to cross one off. (Of course, a rigorous completion KPI came out of the CMMS.)
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Karl Burnett
Solvay, Inc
Anderson SC
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Original Message:
Sent: 05-26-2022 07:38 AM
From: Amr Abdulrahman Mohammed Mahmoud
Subject: Shutdown/turnaround KPIs
Thank you Torbjorn for your valuable support, it is not my first SD but i think the kpis you mentioned are enough, or you think i should use more?
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Amr Abdulrahman Mohammed Mahmoud
Wastani
1st New Cairo
Original Message:
Sent: 05-25-2022 09:19 PM
From: Torbjorn Idhammar
Subject: Shutdown/turnaround KPIs
Hello Amr,
Your KPI sounds like a good start to me. Remember to define what a "scheduled job" is. To do that you need a cut off time. Depending on the size of the shutdown, you can decide how many weeks out you want the cut off time to be. So, for example, if your cut of is 3 weeks before start, I would measure the two things you mentioned. % jobs completed that was scheduled before the cut-off, then % jobs added-on after the cut-off time (unscheduled work). Remember only PLANNED jobs should end up on a Shutdown schedule.
In addition, I would measure how many hours the shutdown start may move, duration move and how many hours the schedule startup moves.
I would also do a critique meetings after the shutdown. You should have a standard meeting and evaluation form for each shutdown.
There are many more things to measure, but if this is your first SD, it may be enough?
Best of Luck.
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Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC
Original Message:
Sent: 05-25-2022 08:23 PM
From: Amr Abdulrahman Mohammed Mahmoud
Subject: Shutdown/turnaround KPIs
Hello everyone,
i getting ready to manage the upcoming turnaround in my company, and i was asked to prepare some KPIs to measure the turnaround progress, i only had two KPIs in mind, which i will use, the are the scheduled activities completion percentage, and the unplanned to planned activities ratio.
in you opinion, do you think there is more kpis to be measured?
thank you all for your time.
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Amr Abdulrahman Mohammed Mahmoud
Wastani
1st New Cairo
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