When a business has to frequently make use of large facilities such as factories, industrial plants and refineries, routine turnarounds are necessary. During a turnaround, the daily operations in the facility come to a halt and maintenance is performed on the machinery. Useful as this practice is for keeping operations running smoothly, turnarounds can be dangerous if they are mishandled. If a few common mistakes are avoided, it should be smooth sailing.
- Bad Planning – Turnarounds are complex endeavors, and often several machines need expert maintenance at once. Strong logistics must be a top priority.
- Messy Scheduling – Scheduling for turnarounds is not just about knowing where every worker is, it is also about coordinating the arrival of necessary new components.
- Ineffective Communication – The people in charge of organizing the turnaround must be able to coordinate the actions of everyone involved, otherwise things may go unchecked.
- Not Minding Prior Turnaround Data – Though some of the same pieces of equipment might need to be attended to, turnaround are never completely identical. However, previous data is still useful in that it allows for better budgeting and for precautions to be taken.
- Vague Objectives – If people in the company aren’t aware of the goals toward which they are working, it becomes difficult to ensure that everyone is on task.
- Mismanaged Budgeting – It is important for the company’s money to be managed well, but setting overly tight budgets can frustrate people, while overlarge budgets can turn into money sinks.
- Cutting Too Many Expenses – It is true that turnarounds are often quite expensive, so it is natural to look for ways to save money. However, this shouldn’t be done at the expense of a properly done job.
- Delaying Replacements or Repairs – While a company might be spending a great deal of money on the labor and parts necessary to keep things running well, choosing to delay essential repairs or replacements can end up costing far more in the long run and risks a dangerous incident occurring.
- Lack of Cost Control – Even though many of these mistakes come from being overly rigid with costs, letting too much money be spent can also be majorly detrimental.
- Going With the Lowest Bidder – It is crucial that companies looking for people to perform a turnaround do their research. Just because a group offers to do the job at the lowest price doesn’t mean they deserve the company’s money.
- Not Obeying Maintenance Procedures – While it might be tempting for some workers to cut corners and ignore instructions in the process, this must not be allowed as it puts people at risk.
- Ineffective QA/QC – It is of tremendous importance that all processes and equipment are checked during a turnaround so that workers are safer and the products produced are of a high quality.
- Poor Training – Anyone who performs work on a turnaround must be properly trained to ensure that the job is done correctly and in a timely manner.
- Lack of Department Communication – For a turnaround to be effective, all departments must be on the same page. If not, important things can go without attention.
When it comes to turnarounds, companies must cover all their bases. Polaris has the means to make this happen.