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6 Phases of STO Excellence
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Reliox
6 Phases
of Shutdown & Turnaround Excellence
60 Questions · TAR Lifecycle
TAR Lifecycle
Full lifecycle from
initiation to continuous improvement
. Each phase builds on the last — every day of overrun costs
$1-5M in lost production
. All phases equally weighted, simple average scoring.
⚙
TAR Cycle
Continuous Loop
1
Initiation & Strategy
Scope definition, risk assessment, stakeholder alignment
10 questions
2
Planning & Preparation
Work list development, scheduling, resource mobilization
10 questions
3
Execution Management
Field supervision, safety, quality, daily progress tracking
10 questions
4
Commissioning & Startup
Pre-startup safety review, phased restart, handover
10 questions
5
Close-Out & Review
Lessons learned, cost reconciliation, performance analysis
10 questions
6
Continuous Improvement
Benchmarking, KPI trending, best practice integration
10 questions
Project Timeline Intensity
P1: Initiate
P2: Plan
P3: Prepare
P4: EXECUTE
HIGH INTENSITY
P5: Close
P6
T-18 months
T-12 months
T-3 months
EXECUTION
T+6 wks
T+3 mo
All phases: equal weight
Simple average scoring
Total:
60q
$
0
,
0
0
0
,
0
0
0
PER DAY OVERRUN
Maturity Scale (1.0 – 5.0)
Innocent
< 1.8
›
Aware
1.8 - 2.6
›
Developing
2.6 - 3.4
›
TARGET
Competent
3.4 - 4.2
›
Excellent
≥ 4.2
Cost of Overrun
Every Day Overrun Costs $1-5M
HIGH STAKES
$0
per day lost production
during overrun
0%
typical overrun longer
vs. planned duration
<5%
best-in-class variance
on-time, on-budget
Planned duration
Baseline
Typical overrun
+25-50%
Reactive vs. Excellence
Reactive
VS
Excellence
25-50%
<5%
Budget Overrun
20-40%
On-time
Schedule Overrun
Multiple
Zero Harm
Safety Incidents
The Business Case
Cost Reduction
15-30%
reduction in
total turnaround cost
Daily Overrun Cost
$1-5M
daily cost of
unplanned overrun
Without Excellence
25-50%
typical
budget overrun
without excellence program
Safety Target
Zero Harm
safety target with
mature STO process
Turnaround duration reduction through better planning
-20-35%
Budget variance improvement
< ±5%
Safety performance with zero harm philosophy
-80% incidents
Asset availability increase from shorter turnarounds
+10-15 days/yr