• Initial assessment : An evaluation of current practices to identify potential gains.
  • “Shutdown Coordinator” role : Establishing a key position to orchestrate shutdowns several months in advance. This role relied on standardised schedules and a best practices guide to prepare, execute, and restart production effectively.
  • Involving stakeholders : Including production, maintenance, EHS (Environment, Health, and Safety), quality, unions, and management.
  • Methodology : Using the DMAIC approach (Define, Measure, Analyse, Improve, Control) to structure the project and monitor results.
Réflexion Projet POMEX
  • Backwards planning : Creating a standardised timeline for each stage – preparation, execution, and recommissioning of equipment.
  • Phase optimisation : Sequentially shutting down and restarting specific zones to better distribute the workload and avoid bottlenecks.
  • Eliminating constraints : Adapting maintenance tasks to seasonal conditions (e.g., servicing boilers and cooling systems) to ensure smoother operations.
  • Increased production : Savings of several million euros due to shorter shutdown periods.
  • Preserved reliability : Critical equipment received a dedicated maintenance period, ensuring quality without compromising production.
  • Improved restarts : Standardised processes enabled faster and safer production resumption.
  • Dedicated “Shutdown Coordinator” : A dedicated manager oversees the preparation and optimal execution of future shutdowns.
  • After Action Review (AAR) : Systematic feedback sessions to refine practices after each technical shutdown.
  • Scaling the model : Shutdowns were coordinated by building and staggered throughout the year to optimise resource management.
  • Diverse industries : Applicable wherever ramp-down and ramp-up periods are necessary.
  • Change management : A people-centred approach to overcome resistance and encourage engagement.
  • Standardised tools : The DMAIC framework ensures a rigorous and reproducible process across all industrial environments.