How to achieve Excellence in Turnarounds

Thru Effective Human Resource

Management

1

Contents

• Company Profile

• Turnaround - FFC Experience

• Human Resource Management

• Optimizing Human Resource

• Impact on Turnaround Performance

• Concluding Remarks

2

We are located at:

FFC-Gothmachhi

(02 Plants)

FFC-Mirpur Mathelo

(01 Plant)

Karachi

Islamabad

Pakistan

3

Company Profile

4

Preventive / Corrective Maintenance

Turnaround – FFC Experience

Philosophy

Replacements & improvement

Projects

Statutory inspections

Improved Efficiency Enhanced Reliability

Revitalized Plant

5

Timely Completion

Within Assigned Resources

Incident Free

Turnaround Goals

Turnaround – FFC Experience

Successful Turnaround

6

Turnaround – FFC Experience

Assisting

Pakistani

Companies

Participating

in TA’s of

International

companies

30

Turnarounds

in 28 Years

7

Human Resource Management

Acquiring Human Resource

Tackling Challenges

Optimizing Manpower

Maintaining Records

8

Human Resource Management

Human Resource Structure in FFC Turnaround

71 %

9

Meeting

Competency

Requirements

Human

Resource

Availability

Achieving

Safety

Objectives

Tackling

Behavioural

Issues

Defining Key

Competencies

Human Resource Management

Challenges

10

Challenges in Human Resource

Type of

Equipment

Nature of JobCriticality of

Job

Defining Key Competencies

COMPETENCY REQUIREMENT

11

Pre-qualification thru Committee

Education & Experience

Test and interviews

Approval

Data Entry

Selection

Meeting Competency Requirements

12

Mandatory Safety Induction Program

13

Understand Plant Safety Requirements

Objective

Learn Safe Working Procedures

Use of PPEsAwareness of Hazards

Mandatory Safety Induction Program

14

Challenges in Human Resource

Free boarding &

lodgingAttractive

Remuneration

Privileged

WorkplaceMedical

Coverage

Congenial Work

Environment

Motivational

Measures

Subsidized

Meals

15

Seamless performance

during Turnaround,

demands efficient

handling of issues

relating to human

behaviors.

Safety Violation

Job Quality

Carelessness

Misconduct

Tardiness

Punctuality

Hostile Attitude

Tackling Behavior Based Issues

16

Optimizing Human Resource

Adjust Resources

Schedule Resources

Prepare Resource Loading Plans

Daily Progress Analysis

Optimizing

17

Overall Manpower Loading Plan (Typical)

18

0

200

400

600

800

1000

1200

1 2 3 4 5 6 7 8 9 10 11 12 13

N U

M B

E R

D A Y S

PLANNED

ACTUAL

Skilled Workforce Loading Plan -Typical

19

4%

10%

19%

28%

38%

48%

58%

66%

74%

80%85%

90%93% 95% 96% 97% 98% 99%

100%

0%3%

10%

16%

27%

39%

50%

61%

70%

77%

0%

20%

40%

60%

80%

100%

120%1

2-O

ct

13

-Oct

14

-Oct

15

-Oct

16

-Oct

17

-Oct

18

-Oct

19

-Oct

20

-Oct

21

-Oct

22

-Oct

23

-Oct

24

-Oct

25

-Oct

26

-Oct

27

-Oct

28

-Oct

29

-Oct

30

-Oct

31

-Oct

01

-No

v

PLAN

ACTUAL

99.7%

1%5%

14%

25%

35%

44%

53%

61%

67%

74%

80%

86%

92%96%

98% 99% 100%

1%4%

11%

20%

34%

48%

59%64%

74%

82%

0%

20%

40%

60%

80%

100%

120%

PLAN

ACTUAL

0%

7%

17%

29%

39%

51%

62%

72%

81%

88%

93% 95% 97% 98% 99.9% 100%

0% 1%

21%

36%

42%

58%

68%

75%79%

87%

0%

20%

40%

60%

80%

100%

120%

PLAN

ACTUAL

Daily Progress Analysis

Planned duration : 416 Hrs

Projected duration: 425 HrsOverall TA Plan

Planned duration : 332 Hrs

Projected duration: 340 Hrs

Urea Unit

F-201

19

26

18

8

10

4

0

5

10

15

20

25

30

35

100 RT HT / RT UREA GRADE JOINTS

PLANNED

ACTUAL

Status of HT/RT Jobs

20

Impact on Turnaround Performance

Effective Utilization of Resources has a lasting impact

on Turnaround Performance, where a slackness can

cost heavily and may result in:

−Extension in Turnaround Duration

−Poor Safety Performance

−Reduced Plant reliability and Efficiency

21

Impact on Turnaround Performance

Improved Efficiency

Schedule compliance

Enhanced Plant

Reliability

Safety Performance

22

Turnaround Cycle

Plant Turnaround interval has

improved from 1 year to ~ 3 years

23

Production increase

- Ammonia > 100 MTPD

- Urea ~ 125 MTPD

Energy consumption improvement

Before TA After TA

- Gcal / MeT Urea 6.70 6.38 [Gain 5%]

- Gcal / MeT NH3 >8.85 8.37 [Gain 5.5%]

- Nmc / MeT Urea 1080 1030

Improved Efficiency & Productivity

Statistics After Turnaround 2009 of Plant-I

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SAFETY PERFORMANCESAFETY PERFORMANCESAFETY PERFORMANCESAFETY PERFORMANCE

25

Planned vs. Actual Durations (P-I)

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FFC has excelled in Turnarounds through

effective human resource management and

achieved:

Concluding Remarks

− Outstanding Safety Performance

− Enhanced Plant reliability

− Improved Plant Efficiency

− Optimum Turnarounds Duration

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Questions

28

From Fauji Fertilizer Company

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