Shutdown Turnaround Optimization Process Certification Training

Are your shutdowns/turnarounds costing you valuable production time?

MGT's Shutdown Turnaround Optimization Program training teaches you how to stay on budget and minimize downtime through a 6-step process that focuses on countdown actions, tools, and resource optimization.

This course aligns with SMRP's Work Management Pillar in the Body of Knowledge.

What is your strategy for minimizing downtime and cost while maintaining a high level of safety?

This training and implementation focus on the vital phases that ensure efficient execution, improved safety, minimized downtime, and maximum use of resources. You'll learn how to challenge the status quo, use risked based work selection, assign the right resources, plan strategies to reduce duration, to integrate schedules, involve operations, and effective closeouts.

Enroll now and enhance your competence and knowledge.

Module 1: Introduction & Course Overview

• Objectives and expected outcomes
• Definitions: Shutdown, Turnaround, Outage, TAR, STO
• The Shutdown/Turnaround Life Cycle
• Link to SMRP Work Management Pillar



Module 2: Strategic Justification & Business Alignment

• Shutdown drivers (regulatory, safety, reliability, production optimization)
• Determining optimum shutdown frequencies
• Cost vs. risk vs. production considerations
• Aligning shutdown events with asset management strategy



Module 3: Shutdown Organization & Governance

• Governance structures and roles
• Steering committee vs. execution team
• RACI matrices for planning, execution, and closeout
• Communication pathways across Operations, Maintenance, Procurement, Safety, Contractors
• Workshop 1: Create a high-level governance model and RACI chart for a sample plant shutdown.



Module 4: Work Identification & Validation

• Work request intake and screening
• Asset criticality methodology (risk/criticality ranking)
• Work verification and approval processes
• Scope growth and scope freeze rules



Module 5: Risk-Based Work Selection

• RIME (Risk, Importance, Mission, Economic) prioritization
• Failure modes & risk assessment fundamentals
• Balancing shutdown vs. routine maintenance tasks
• Deciding what must be done during shutdown



Module 6: Cost Estimating & Budget Development

• Cost categories (labor, materials, contracts, contingency)
• Bottom-up and top-down estimating techniques
• Managing cost creep
• Workshop 2: Prioritize a sample work list using a risk-based methodology.



Module 7: Detailed Shutdown Planning

• Job planning standards (work packs, job steps, photos, drawings, permits)
• Material planning & procurement integration
• Spare parts strategies (critical spares, long-lead items, kitting)
• Contractor selection and prequalification



Module 8: Scheduling for Efficiency

• Building the integrated master schedule
• Critical path method (CPM) and sequencing logic
• Manpower loading and leveling
• Use of scheduling software (Primavera/MS Project/CMMS integration)



Module 9: Pre-Shutdown Readiness & Checklists

• Pre-shutdown risk assessments
• Pre-start safety review (PSSR) inputs
• Lockout/tagout planning
• Readiness reviews & gate checks
• Workshop 3: Develop a simplified shutdown schedule and identify critical-path activities.



Module 10: Execution Readiness

• Mobilization planning
• Contractor coordination procedures
• Field supervision structures



Module 11: Safe Execution Practices

• Permit to work & isolation management
• Confined space, hot work, lifting operations
• Process safety integration
• Hazard identification tools (LOTO, JHA, TRA)



Module 12: Daily Management of the Shutdown

• Shift meetings & progress tracking
• Managing change, delays, and deviations
• Work-front management
• Real-time reporting & dashboarding
• Managing rework and quality assurance



Module 13: Startup & Commissioning

• Startup risk considerations
• Handover from maintenance to operations
• Commissioning checklists & system verification
• Workshop 4: Simulate daily decision-making based on progress reports, delays and scope changes.



Module 14: Shutdown Closeout Activities

• Demobilization planning
• Contractor performance evaluation
• Documentation capture (CMMS updates, as-builts, lessons learned)



Module 15: Post-Shutdown Analysis

• KPIs: schedule variance, cost variance, safety performance, work quality
• Benchmarking & performance dashboards
• Root-cause evaluation of variances



Module 16: Lessons Learned & Preparation for the Next Event

• Structured lessons-learned methodology
• How to run a high-value closeout meeting
• Incorporating lessons into future planning cycles
• Updating long-term shutdown strategy
• Workshop 5: Create a final closeout report with KPIs, findings and improvement recommendations.

• Basic knowledge of operations and maintenance processes
• Familiarity with plant equipment and workflows
• Experience with project management or work planning (preferred but not mandatory)
• Understanding of safety procedures and regulatory compliance in industrial settings

• Plant Managers and Operations Leaders
• Maintenance Managers and Engineers
• Project Managers responsible for shutdowns/turnarounds
• Safety and Reliability Professionals
• Procurement, Contracting and Scheduling personnel involved in shutdown planning

• 20 multiple-choice questions covering all course modules
• Passing requirement: at least 15 correct answers
• Two attempts allowed to achieve a passing score
• Certificate issued upon successful completion of the exam

Obtaining the Shutdown & Turnaround Optimization Certification with training equips professionals with the practical knowledge and structured methodologies needed to plan, execute and optimize shutdowns and turnarounds - critical activities in asset‑intensive industries such as oil & gas, petrochemicals, power generation, mining and manufacturing. Through guided instruction, participants learn how to develop effective schedules, coordinate multi‑disciplinary teams, manage contractors and resources, and implement risk mitigation measures that improve safety, reduce unplanned downtime and enhance execution efficiency. This certification helps professionals understand best practices and industry standards, enabling them to transition from reactive firefighting to proactive, systematic shutdown planning and performance improvement.

From a career and financial perspective, certification accompanied by structured training can significantly enhance your credibility, employability and salary potential. Roles such as Turnaround Planner, Maintenance & Reliability Manager, Operations Manager and Project Coordinator often command above‑average compensation due to their impact on operational performance. Certified professionals in these roles may see annual salaries ranging from $70,000 to $110,000 or more, with senior or specialized positions in large energy or manufacturing firms exceeding $120,000 depending on location and experience. By combining validated expertise with real‑world application, participants not only elevate their professional profile but also deliver measurable value to their organisations, making this training a strategic investment in both skills and career advancement.

He is a seasoned operations and maintenance optimization expert with extensive experience planning, executing and improving shutdown and turnaround activities across industrial and process‑driven environments. With deep expertise in turnaround strategy, risk mitigation, resource coordination and performance improvement, he brings practical, real‑world insights to help learners enhance efficiency and minimize downtime. Known for his clear and engaging training style, he simplifies complex scheduling and execution concepts into actionable practices that can be applied immediately on the job. His guidance equips professionals to implement best‑in‑class turnaround planning, optimize maintenance outcomes and deliver measurable operational improvements.

By the end of this course, participants will be able to:

• Explain the complete shutdown and turnaround life cycle, including key terminology, phases, and governance structures for successful execution.
• Align shutdown strategy with organizational goals by evaluating drivers, risks, costs and production considerations.
• Develop effective governance models, roles and communication pathways that support coordinated shutdown planning and execution.
• Identify, validate and prioritize shutdown work using risk-based methodologies to optimize scope and resource allocation.
• Create accurate cost estimates and budgets for shutdown events, using both bottom-up and top-down techniques.
• Build detailed integrated shutdown plans and schedules (using CPM and other tools) that minimize downtime and enhance coordination.
• Apply safety, risk assessment and readiness planning tools to ensure shutdown preparedness and compliance with safety protocols.
• Manage real-time shutdown execution, including daily progress tracking, change control and field coordination.
• Conduct effective startup and commissioning activities, ensuring smooth transition back to operation with minimal setbacks.
• Evaluate shutdown performance using key performance indicators (KPIs), document lessons learned and update strategies for future optimization.