Are you still relying on spreadsheets, outdated software, or paper-based systems to plan and execute your Shutdowns, Turnarounds, and Outages?
Industrial asset maintenance is one of the most significant operational and financial challenges in the process sector. Shutdowns and turnarounds can cost millions to execute, and even small delays or missteps can have a disproportionate impact on production and profitability. In sectors like energy, manufacturing, and transportation, unexpected downtime can be extremely costly, averaging around $250,000 for every hour of inactivity, which adds up to approximately $2 million throughout a standard workday. Despite these high costs, many organisations still rely on spreadsheets to manage the planning and execution of these complex events.
While familiar and accessible, spreadsheets often fall short when it comes to the demands of modern maintenance operations, lacking the transparency, control, and scalability required for effective shutdown management. The true cost of this outdated approach can escalate quickly, undermining both efficiency and commercial performance.
In this article, we’ll examine the limitations of spreadsheet-based planning, explore the operational risks it creates, and introduce purpose-built STO software that not only streamlines the process, but delivers measurable returns. Let’s explore why now is the time to rethink your approach.
The Hidden Costs of Spreadsheets
Spreadsheets may be accessible, familiar, and inexpensive to implement, but they introduce significant challenges when used for managing complex shutdown and turnaround projects:
- Data Silos: Critical information often becomes fragmented across departments, leading to inconsistencies, duplicated efforts, and miscommunication.
- Manual Errors: Relying on human data entry increases the risk of mistakes, which can trigger delays, rework, or even safety incidents.
- Lack of Real-Time Visibility: Static, disconnected data hinders timely decision-making, especially in fast-moving shutdown environments where agility is essential.
While spreadsheets may appear cost-effective on the surface, their limitations often lead to extended downtime, cost overruns, and compromised compliance—ultimately costing your organisation far more in the long term.
Embracing Digital Transformation with Turnaround Planning Software
Developed over two decades with insights from industry leaders like BP and Altrad, iPlanSTO offers a comprehensive solution for shutdown and turnaround planning. This enterprise resource management system integrates predictive analysis and preventative maintenance strategies to optimise operations.
Key Features:
- Real-Time Transparency: Provides up-to-date information, enhancing work order management and highlighting critical activities that impact commercial returns.
- Performance Benchmarking: Allows comparison of individual and team performance, fostering healthy competition and informed managerial discussions.
- Integrated Reporting: Utilises tools like Power BI to highlight issues in real-time, enabling prompt investigation and action.
- Scenario Analysis: Processes vast amounts of data quickly, allowing for informed decision-making through various simulated scenarios.
- Efficiency Gains: Digitising tasks reduces preliminary work by up to 50%, with activities that previously took a week now completed in hours.
- Error Identification: Technology-driven error detection simplifies issue resolution, minimizing rejections or overpayments.
- Resource Optimisation: Streamlines tasks, reducing the need for large headcounts while fulfilling obligations effectively.
The Cost of Inaction
Maintaining outdated systems isn't just inefficient—it's expensive. Companies have reported significant savings and performance improvements after adopting iPlanSTO:
- £1.7 Million Reduction: Achieved substantial cost savings without compromising service quality.
- 25% Increase in Supervisor Ratios: Enhanced oversight and efficiency in operations..
- Standardised Work Pricing: Ensured consistency and compliance in line with agreed measurement methods.
Overcoming Resistance to Change
Transitioning from spreadsheets to a dedicated software solution can be daunting. Turnarounds never pause for new systems — and we get that. However, the risks of remaining with outdated systems far outweigh the challenges of change. iPlanSTO's user-friendly interface and comprehensive support make the shift seamless, ensuring teams are equipped to handle modern demands. Our experts work alongside your team to implement your new software with minimal disruption.
Conclusion
In an industry where precision, efficiency, and safety are paramount, relying on spreadsheets is a liability. Using the incorrect tools can lead to wasted planning effort, incorrect labour forecasts, significant cost overruns, and your plant failing to return to service as scheduled. Embracing advanced solutions like iPlanSTO not only mitigates risks but also unlocks opportunities for growth and excellence.
