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How to Use the Tools
- 1. 908 770 4955 www.theoutageexpert.com __________ ________________________ Outage Fundamentals How to use the tools
- 2. 908 770 4955 www.theoutageexpert.com __________ ________________________ Zone Outage Control™ Will reduce cost and schedule by 10% for three outage cycles.
- 3. 908 770 4955 www.theoutageexpert.com __________ ________________________ For example: An outage cost of $3,000,000 An outage duration of 21 Days An down day cost of $50,000
- 4. 908 770 4955 www.theoutageexpert.com __________ ________________________ Zone Outage Control™ will save you 10% on cost or $300,000 10% on schedule or 2.1 days at $50,000 a day or $105,000 For a total savings of $405,000
- 5. 908 770 4955 www.theoutageexpert.com __________ ________________________ Zone Outage Control™ will give you cost to date and cost to finish 4 hours after the end of each shift with minimal effort.
- 6. 908 770 4955 www.theoutageexpert.com __________ ________________________ Zone Outage Control™ will reduce and eventually eliminate downtime due to poor outage close out. (100% availability for 18 months post outage)
- 7. 908 770 4955 www.theoutageexpert.com __________ ________________________ Boiler Book Organization of information (remember the waltz) All the information in one place Inspection documents creation Material and spares ordering
- 8. 908 770 4955 www.theoutageexpert.com __________ ________________________ Working Schedule First schedule the shutdown/open and ready for work hour by hour • Get ops / maintenance / engineering to give you their schedules Then schedule the zones • Get the contractors and lead man to develop a shift by shift task list and manpower loading then review Then schedule unit testing • Get ops to give you their timing Then the start up • Get ops to give you their timing
- 9. 908 770 4955 www.theoutageexpert.com __________ ________________________ Get everyone to buy in after the schedule is roughed in.
- 10. 908 770 4955 www.theoutageexpert.com __________ ________________________ Get commitment from everyone. Upper Management Management Operations Maintenance Engineering Safety All Contractors All Lead Men
- 11. 908 770 4955 www.theoutageexpert.com __________ ________________________ Cost Control Dashboard Take the working schedule and monazite it shift by shift and contractor by contractor in excel
- 12. 908 770 4955 www.theoutageexpert.com __________ ________________________ Follow the outage calendar.
- 13. 908 770 4955 www.theoutageexpert.com __________ ________________________ Get all the mental soak time you can Constantly mentally rehearse everyone’s part.
- 14. 908 770 4955 www.theoutageexpert.com __________ ________________________ Build a team out of different departments and companies.
- 15. 908 770 4955 www.theoutageexpert.com __________ ________________________ Have as many lead men and contractor meetings and lunches before the outage.
- 16. 908 770 4955 www.theoutageexpert.com __________ ________________________ Everyone needs to know their part.
- 17. 908 770 4955 www.theoutageexpert.com __________ ________________________ Choose an Outage Manager. The Outage Manager chooses a night manager.
- 18. 908 770 4955 www.theoutageexpert.com __________ ________________________ Once the bell rings In shutdown / LOTO / open and ready for work, the outage manager needs to be there for each hand off of work.
- 19. 908 770 4955 www.theoutageexpert.com __________ ________________________ Daily outage meetings. Twice a day (morning and night) With leadmen and contractor foreman.
- 20. 908 770 4955 www.theoutageexpert.com __________ ________________________ SAFETY FIRST Near misses written Near misses closed General concerns Site conditions Upcoming dangerous tasks Contractor coordination
- 21. 908 770 4955 www.theoutageexpert.com __________ ________________________ Have a zone chart. Only talk about what will be done in next 12 hours Never accept “That should be done by shift change”
- 22. 908 770 4955 www.theoutageexpert.com __________ ________________________ Make everyone aware that they need to answer the question you asked or else
- 23. 908 770 4955 www.theoutageexpert.com __________ ________________________ Collect timesheets at every meeting.
- 24. 908 770 4955 www.theoutageexpert.com __________ ________________________ Buy donuts and coffee.
- 25. 908 770 4955 www.theoutageexpert.com __________ ________________________ Outage meeting should only be 15 minutes to half an hour.
- 26. 908 770 4955 www.theoutageexpert.com __________ ________________________ Create a team of all involved.
- 27. 908 770 4955 www.theoutageexpert.com __________ ________________________ Call the ball when it’s time to shift between assess and elbows and close outs.
- 28. 908 770 4955 www.theoutageexpert.com __________ ________________________ PRINT OUT ENDING MILESTONES IN LARGE PRINT AND HANG THEM EVERYWHERE.
- 29. 908 770 4955 www.theoutageexpert.com __________ ________________________ Inspections and Outage Report Review all as found sheets Create work scopes from as found inspection documents Get all close out/as left documents Keep all the originals in a three ring binder and that’s your outage report
- 30. 908 770 4955 www.theoutageexpert.com __________ ________________________ As outage manager, keep these basic principles in mind: Keep everyone focused on what’s next and the end of the outage Declare when the outage is over (date and time) loudly as possible days before your appointed date and time If a job site looks like a mess it is, stop and get it right or you will fight it all outage
Editor's Notes
- Zone Outage Control Will reduce cost and schedule by 10% for three outage cycles
- Slide 2 Zone Outage Control Will reduce cost and schedule by 10% for three outage cycles Phase in the following
- Slide 2 Zone Outage Control Will reduce cost and schedule by 10% for three outage cycles Phase in the following
- Zone outage control will give you cost to date and cost to finish 4 hours after the end of every shift with minimal effort
- Zone outage control will reduce and eventually eliminate downtime due to poor outage close out (100% availability for 18 months post outage)
- Boiler book Organization of information (remember the waltz) All the information in one place Inspection documents creation Material and spares ordering
- Working schedule First schedule the shutdown/open and ready for work hour by hour Get ops/maintenance/engineering to give you their schedules Then schedule the zones Get the contractors and leadman to develop a shift by shift task list and manpower loading then review Then schedule unit testing Get ops to give you their timing Then the start up Get ops to give you their timing
- Working schedule Once you have the schedule roughed in then get buy in and commitment from everyone Upper Management (The Money) Management (The Boss) All departments Ops Maintenance Engineering Safety All contractors All leadman
- Upper Management (The Money) Management (The Boss) All departments Ops Maintenance Engineering Safety All contractors All leadman
- Cost control dashboard Take the working schedule and monazite it shift by shift and contractor by contractor in excel
- Cost control dashboard Take the working schedule and monazite it shift by shift and contractor by contractor in excel
- Get all the mental soak time you can You want to constantly mentally rehearse everyone part in the play with them
- You need to build a team out of different departments and company’s
- It helps to have as many leadman and contractor meetings and lunches before the outage
- Everyone need to know their part (Money and schedule that their part contributes to the outage)
- Pick and Outage manager who is responsible for the whole thing The outage manager needs to pick a night manager
- Once the bell rings In shutown/loto/open and ready for work the outage manager needs to be there for each hand off of work (it’s a relay race and people don’t like to give up the batton)
- Daily outage meetings 2 a day (morning and night) With Leadmen and contractor forman
- Safety first Near misses written Near misses closed General concerns Site conditions Upcoming dangerous tasks Contractor interferences
- Have a zone chart and then go through the zones with whats expected on the next shift and when you expect them to be done Only talk about whats done and going to be done in the next 12 hours Never accept “That should be done by shift change”
- Make everyone aware that they need to answer the question you asked or else (skull and cross bones)
- Timesheets (have someone get all the time sheets)
- Buy dougnuts and coffee
- Should only be 15 minute to a half hour no matter how large the outage
- Create a team of all involved
- Call the ball when its time to shift between asses and elbows and close out (It’s been lovely having you no get the F**K out!!)
- Put up in large print ending milestone (Boilers hydro, turbines is full speed no load etc etc)
- Inspections and outage report Review all as found sheets Create work scopes from as found inspection documents Get all close out/as left documents Keep all the originals in a three ring binder and that’s your outage report
- Basic principles to always keep in mind as the outage manager Keep everyone focused on whats next and the end of the outage Declare when the outage in over (date and time) loudly as possible days before your appointed date and time If a job site looks like a mess it is, stop and get it right or you will fight it all outage