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4 Steps for a Smooth Facility Shutdown

Posted By Tom Felstead On September 17, 2018

The word “shutdown” to manufacturing and production facilities renders hesitation. Every day, hour, and second is money lost when production lines are offline. There is extensive pressure to maintain high output and avoid as many backups as possible. With these concerns considered, shutdowns require an extreme amount of coordination, scheduling, and preparation, especially since Food and Beverage manufacturing facilities, Power and Energy stations, and Auto manufacturing facilities are all different in nature. There are new, unique challenges at every shutdown and every moment is a cost to the client. To get facilities back up running as soon as possible, we have developed four steps necessary to prepare for the uniqueness of every facility and reduce the stress of a shutdown.

Coordination of Trades

The first order of operations is determining the coordination of the different trades. Many facilities have limited space and need to coordinate the trades in a proper sequence because being on time is of the essence with a shutdown. As a Construction Manager (CM) who self-performs in various trades, our success has come from self-performing as much of the work as possible. A CM’s ability to self-perform many portions of a project allows them to set the pace and quality of work, maintain the budget, and adjust manpower and equipment as neccessary. A CM with multiple skilled trades under one hardhat leads to better coordination and greater efficiency for shutdowns of any kind.

Usage of BIM

The usage of Building Information Modeling (BIM) and Laser Scanning are extremely useful tools that are used before a shutdown to begin work off-site. BIM helps our team analyze and coordinate existing conditions and obstacles, restrictions, equipment sizes and clearances, new construction, and temporary construction methods before the work starts. To gather data on the existing facility, Laser Scanning can be utilized. Laser scanning captures as-built data rapidly and precisely. This data, known as a point cloud, is a perfect 3D as-built of existing conditions. The point cloud can then be inserted into various 3D modeling platforms, allowing the Owner and all the trades to have consistent, accurate building data. See how JP Cullen applied Laser Scanning at a Fortune 500 Food and Beverage Company project saving the Client $130,000.

Prefabrication

Time is of the essence, and it should not be wasted on assembling parts and equipment that could be done before the shutdown process. Our answer to saving time and money in an aggressive shutdown process is through prefabrication. This service offers a streamlined process that will result in fewer errors of installation and time wasted, translating to schedule savings and cost savings. With the materials prepared ahead of time offsite, the shutdown process timeline narrows and the traffic of materials lessens. Learn more about JP Cullen’s beneficial prefabrication service here.

Clean Room Practices and Employee Safety

Whether the facility is a national Food and Beverage manufacturer or Power and Energy producer, safety is of the utmost importance. Noise, dust, and other disruptions due to construction within a facility can be a headache. JP Cullen has developed Clean Room Practices that we implement into each of our shutdowns. The usage of clean room practices allows the client to maintain the surrounding production while remaining profitable. Air-monitoring and temporary walls are a few avenues in which JP Cullen delivers Clean Room Safety Practices. These practices come from our experience working with national Fortune 500 Food and Beverage, Manufacturing, Healthcare, and Power clients. In addition to our Clean Room Practices, we make it a priority to understand our client’s specific safety policies and procedures as well and train our team from within prior to beginning work at their facility. Safety is always the number one goal.

Whether you are looking at a 5-day shutdown or a 3-month shutdown, JP Cullen has a variety of shutdown experience in the Food and Beverage, Chemical, Auto manufacturing, and Power and Energy industry. Consider these four steps for a smooth, successful shutdown that won’t leave you with a headache.

Filed Under BIM, Industrial, JP Cullen, Safety