About the Customer
The customer is one of the world’s largest refineries, processing 400,000+ barrels per day with a Nelson Complexity Index of 11+. The refinery uses SAP ECC 6.0 for enterprise operations and manages complex Scheduled Turnaround (STO) projects critical to operational continuity.
Business Scenario
The refinery struggled with manual STO planning, leading to delays, cost overruns, and operational inefficiencies. Limited visibility and coordination issues increased project risks, highlighting the urgent need for a structured digital solution to manage turnaround complexity.
Challenges
Operating with manual processes for complex turnaround projects, the refinery faced scope management difficulties, project delays, budget overruns, and procurement inefficiencies.
- Scope Management Complexity – Difficulty in defining and finalizing project scope led to incomplete planning, scope creep, and inefficiencies in turnaround execution.
- Project Delays – Slippage in planned duration impacted overall execution timelines, extending shutdown periods and reducing production capacity during critical turnaround windows.
- Budget Overruns – Uncontrolled costs and resource allocation issues resulted in exceeding planned budgets, affecting profitability and project ROI.
- Material Procurement Issues – Inefficiencies in sourcing and managing materials caused disruptions in project flow, delaying critical path activities and extending turnaround duration.
Solution
Built using Procify, our AI-powered low-code/no-code platform.
The customer implemented Procify STO Manager to streamline STO projects, integrating Scoping, Planning, and Execution into a single SAP-based platform with Tableau-based reporting for real-time insights.
- End-to-End STO Management – Deployed single SAP-integrated solution covering scoping, planning, execution, and reporting, eliminating disconnected systems and creating unified turnaround management platform.
- Mobile-Enabled Field Access – Implemented offline-supported mobile technology with multi-device compatibility, enabling field teams to access and update turnaround data without connectivity constraints.
- Enhanced Task List Master – Configured customized task list master tailored to meet client-specific turnaround requirements, standardizing execution processes across projects.
- Advanced Reporting with Tableau – Developed custom dashboards on Tableau for real-time insights into project progress, resource utilization, cost tracking, and critical path monitoring.
- Streamlined Approvals – Configured flexible approval workflows for better process control, ensuring governance and accountability throughout turnaround lifecycle.
- Seamless Content Integration – Integrated third-party content management system for improved document handling, version control, and collaboration across turnaround teams.
- Optimized Scheduling – Replaced Primavera with Procify STO Manager Gantt Chart for efficient project planning, resource leveling, and critical path management.
Business Impact
- Reduced Project Duration – Streamlined execution processes and better coordination significantly shortened turnaround timelines, minimizing production loss.
- Increased Wrench Time – Improved field productivity and lower operational costs through better planning, material availability, and reduced administrative burden.
- Enhanced Scoping Accuracy – Comprehensive scoping tools and completeness checks resulted in better project outcomes and reduced scope-related delays.
