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Shutdowns and turnarounds are among the most complex and high-stakes events in mining and industrial infrastructure operations. These planned interruptions are intended to restore operational integrity, replace or upgrade major systems, and ensure compliance with safety and environmental regulations. However, while the intent is strategic, the outcomes are often disappointing. Projects run over budget, exceed schedules, and suffer from coordination breakdowns that erode operational performance long after the shutdown ends.
According to a study by Independent Project Analysis (IPA), over 50% of significant shutdowns in the mining sector exceed their planned duration by at least 15%, with cost overruns commonly reaching 25–30%. In worst-case scenarios, poorly executed shutdowns can result in catastrophic equipment failure, loss of the license to operate, or even fatalities. Yet these failures are rarely caused by bad intentions—they’re the result of systemic planning gaps, fractured execution accountability, and the misalignment between owner expectations and contractor deliverables.
To ensure turnaround success, owner organizations must adopt a structured, integrated, and proactive approach to management. This means treating shutdowns not as one-off maintenance events, but as capital projects in their own right—complete with strategic planning, risk analysis, and governance that primary investments demand.
This guide outlines a proven framework to improve shutdown performance, reduce risk, and deliver projects on time and on budget.
TMG specializes in executive and operational consulting for the Mining, Energy, and Infrastructure sectors. We provide tailored oversight and strategic guidance across all project stages, ensuring optimal outcomes from conception to execution.
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