A framework for the successful implementation of turnaround maintenance projects

摘要

The manufacturing sector is of enormous economic and social significance to any state economy and its people. In the UK, the manufacturing sector accounts for about 13% of GDP and employs about four million people representing approximately 14% of the working population. Manufacturing processes depend on the performance of the facility (machines, equipment and tools) and the human resource (labour). These machines and equipment degrade with age and usage and, therefore, require maintenance.Despite the strategies adopted for their maintenance, there comes a time due to age, operating/environmental conditions and statutory requirements when the entire facility had to be shut down for necessary repairs, maintenance and project works. This is called Shutdown Maintenance also known as Turnaround Maintenance (TAM).Although several works have been carried out by organisations and professionals in recent times to optimize TAM projects, organisations are still struggling with TAM projects with reported alarming rates of failure.A preliminary literature review and pilot studies identified that the major cause of TAM project failures are attributed to the use of Engineering, Procurement and Construction (EPC) project management methodologies to manage TAM projects without considering their unique features.Findings from a comprehensive literature review, questionnaire survey and case studies in major process plants in the UK, were used to develop a unique best practice framework (and its components parts) which were validated by very experienced, proactive and industry-based hands-on TAM professionals.The conclusions which are drawn from this research study includes establishment of TAM evaluation criteria, TAM critical success factors, TAM manager selection criteria, TAM management methodologies and the TAM project implementation framework.This best practice framework which is a major contribution to knowledge in this area is recommended for all operators of engineering facilities to ensure the successful implementation of their TAM projects. The findings from the study are also of significant importance to contract organisations, TAM managers and aspiring TAM professionals, government bodies, training organisations and tertiary institutions who are involved in maintenance management in engineering facilities.