The 5-Step Process That Makes Plant Turnarounds Predictably Successful

Defining the Challenge: Shutdowns, Turnarounds, and Outages

In industrial operations, downtime is categorized into two types: unplanned and planned. Typically, a shutdown event occurs when an unplanned equipment failure forces an immediate operational halt.

In contrast, a turnaround event represents a planned closure of an entire plant or facility, undertaken to complete major repairs, upgrades, or maintenance work. Similarly, an outage event refers to a planned partial closure of a specific process, line, area, or machine – scheduled for similar work reasons.

Turnarounds and outages are generally complex and expensive projects executed under extreme time pressure. They require multi-disciplinary coordination, tight scheduling, and excellent resource management.

Due to their uniqueness and complexity, these events must be meticulously planned and prepared for many months before execution. Completion delays can result in massive losses, as full staffing levels and production expectations resume immediately upon restart.

Turnarounds must be executed with the precision of a military campaign — measured in hours and days, not weeks.

High Stakes and the Case for Smart Planning

Plant downtime often results in much more than lost production costs. It can jeopardize market commitments, strain resources, and, in some cases, damage reputation. Therefore, turnaround or outage planning and preparation must begin several months in advance of the event. Properly planned turnarounds not only minimize downtime but also optimize plant performance after the event.

Three key outcomes measure turnaround success: 1) all work completed on time, 2) a safe and efficient plant restart, and 3) achieving all planned performance improvements. These can be achieved by using the five-step approach outlined below.

Five Steps to Turnaround Success

Step 1: Appoint a Turnaround Manager

Turnarounds require dedicated leadership. A turnaround manager must be a full-time appointee or a manager relieved from regular duties, hold decision-making authority, be introduced organization-wide as the turnaround lead, and possess strong project management, communication, and multitasking skills.

Turnaround success starts with a clear chain of command and a single point of accountability.

Step 2: Schedule the Event and Define Its Scope

Mark the turnaround on the corporate calendar early. Break it down into individual projects, with the most complex project determining the total event duration. Communicate event timelines across the organization and issue a call for work requests, with a strict cut-off date for submissions — typically four to five months prior to the event.

Clarity on scope ensures the turnaround team can focus on execution, not late changes.

Step 3: Build a Comprehensive Resource Plan

Resource planning ensures smooth execution. This includes full-time equivalent (FTE) staffing requirements, detailed work orders for every task, designated laydown/staging areas for materials and tools, parking, accommodations, site logistics, permitting, insurance, regulatory compliance, specialized equipment and fuel, and documented shutdown/start-up procedures.

When it’s time to execute, everything must be where it belongs — ready to go.

Step 4: Define Turnaround Outcomes

Establish specific, measurable goals such as completing and testing all work before restarting, installing new systems (e.g., compressed air supply), and achieving performance targets (e.g., increased throughput). Outcomes should drive the schedule and align stakeholders.

You can’t hit the target if you don’t define it clearly.

Step 5: Develop and Execute the Turnaround Schedule

With defined outcomes and resources in place, create a detailed schedule using project management or turnaround software. (Note: turnaround software allows the planner to perform “what-if” scheduling in real-time and view the impact of any changes), address load leveling and crew planning, procurement timelines and delivery windows, task sequencing to avoid bottlenecks and contingency planning for inevitable surprises.

A great schedule makes complexity manageable — and surprises less disruptive.

Turning Downtime into Competitive Advantage

Turnarounds are opportunities disguised as challenges. By following a disciplined five-step process, downtime can be minimized, equipment performance optimized, and plant reliability improved.

Smart shutdowns aren’t just about getting back online — they’re about coming back stronger.

With proactive planning, strong leadership, and precise execution, maintenance and operations leaders can transform turnarounds from a disruptive event into a strategic win.