Extension of activity analysis methodology to maintenance, shutdown, and turnarounds in petrochemical facilities

Studies show that construction productivity has been stagnant for decades. Interestingly, other industries like manufacturing, automobile and agriculture have witnessed a steep increase in productivity, nearly twice, over the same period of time. It has been the norm for many continuous improvement methods, employed by these industries, to claim credit for this trend. While inadequacies in a range of parameters like management practices, organizational behavior, contractual differences, and other planning functions affect poor productivity, the first step towards any improvement program is to measure the existing condition. The importance of measuring and improving productivity has become increasingly critical and significant with raging project capital costs and complexity, especially in the petroleum industry.

This research focusses on providing a productivity language for petrochemical owners and contractors. The developed methodology helps them to communicate improvement strategies with each other and within their organization beyond construction leading into maintenance and shutdown turnarounds. Activity Analysis is a productivity assessment and improvement method developed by the Construction Industry Institute (CII) in 2010.

This thesis describes the adaptation of activity analysis methodology that was developed to measure productivity indicators at petrochemical facilities on construction, maintenance and shutdown turnaround activities between 2015 and 2016. It also provides an overview on the activity analysis software developed for data collection, which is a byproduct of this research. This study also provides a summary of expected trends and challenges in petrochemical industries, and strategies that could be implemented to enhance the direct work rate in both construction and maintenance environment.