Plan and execute plant shutdowns with iFactory's comprehensive turnaround management system. Schedule planned and unplanned shutdowns, track estimated vs. actual costs, manage tasks with critical path analysis, and link work orders seamlessly. From planning to execution, manage your entire shutdown lifecycle — and reduce downtime by 40%.
From initial planning to post-shutdown review, iFactory manages every phase of your turnaround. Define scope, track costs, coordinate work orders, and analyze performance — all in one integrated platform.
Define shutdown scope, set type (Safety, Planned, Unplanned), assign managers, configure approval workflows, and document objectives.
Input estimated costs by category (labor, materials, contractors), estimate production loss, and set budget thresholds with variance alerts.
Link work orders, track critical path tasks, monitor progress in real-time, manage scope changes, and capture actual costs as they occur.
Compare estimated vs. actual costs, analyze schedule performance, document lessons learned, and improve future turnaround planning.
Set shutdown type, assign managers, configure approval workflows, and plan your turnaround with precision. iFactory supports three main shutdown types — Safety Shutdowns, Planned Shutdowns, and Unplanned Shutdowns — each with dedicated tracking and reporting.
Clear identification for each shutdown event with auto-generated IDs.
Safety, Planned, or Unplanned categories with dedicated workflows.
Enable approval requirements with status tracking and notifications.
Assign responsible personnel for oversight and accountability.
Recent Shutdowns
The cost estimation feature allows you to input estimated costs, estimated production loss, actual costs, and actual production loss for each shutdown. The system tracks budget variance in real-time, showing whether you're under or over budget.
Input planned labor, materials, contractors, and equipment costs.
Track actual expenditures as they occur during execution.
Estimate and track production loss value during shutdown.
Real-time budget variance with under/over budget indicators.
Cost Breakdown
Critical path planning identifies the longest sequence of dependent tasks that determines the minimum shutdown duration. By defining critical path duration in hours and tracking critical tasks, you can focus resources on the most time-sensitive activities.
Define critical path in hours to determine minimum shutdown time.
Link dependent tasks to visualize the critical sequence.
Prioritize resources on critical path activities for on-time delivery.
Get notified when tasks consume schedule float or fall behind.
Critical Path Tasks
Seamlessly connect work orders to shutdown events. Assign work orders to individual technicians or vendors, schedule with precise dates, and coordinate all planned shutdown activities. Keep your maintenance team organized and efficient.
Associate work orders directly with shutdown periods.
Assign to team members with availability check.
Assign to external vendors for specialized maintenance.
Set expected duration in hours or days for each work order.
Active Work Orders
Industry-specific shutdown templates, cost tracking, compliance frameworks, and reporting — pre-built to accelerate your turnaround planning and ensure safe, on-budget execution.
FCC, CDU, reformer turnarounds, catalyst changes
Ethylene crackers, polymerization, reactor overhauls
Turbine overhauls, boiler outages, NERC compliance
Production line shutdowns, equipment overhauls
Process train shutdowns, FDA compliance
Mill shutdowns, smelter campaigns, crusher overhauls
Production line changeovers, seasonal shutdowns
HVAC shutdowns, building systems maintenance
"Our last 3 turnarounds with iFactory came in under budget — after 15 years of 10-20% overruns. The cost tracking alone saved us $1.2M on our annual turnaround."
"The critical path tracking changed everything. We can see exactly which tasks are blocking completion and redirect resources in real-time. Shutdown duration dropped from 28 to 21 days."
"Linking all 127 work orders to our shutdown event gave us complete visibility. No more hunting through emails and spreadsheets. Everyone knows exactly what's due."
iFactory supports three main shutdown types: Safety Shutdowns (emergency stops for personnel and equipment protection), Planned Shutdowns (scheduled maintenance windows, annual turnarounds, and preventive maintenance), and Unplanned Shutdowns (emergency breakdowns requiring immediate response). Each type has dedicated tracking and reporting.
The cost estimation feature allows you to input estimated costs, estimated production loss, actual costs, and actual production loss for each shutdown. The system tracks budget variance in real-time, showing whether you're under or over budget with visual indicators.
Critical path planning identifies the longest sequence of dependent tasks that determines the minimum shutdown duration. By defining critical path duration in hours and tracking critical tasks, you can focus resources on the most time-sensitive activities.
Yes, iFactory allows you to seamlessly link work orders to planned shutdown periods. You can assign work orders to individual technicians or external vendors, schedule with precise start and end dates, and track completion in real-time.
For major shutdowns (annual turnarounds), planning should begin 3 to 6 months in advance. This allows time to define scope, order long-lead spare parts, contract specialized labor, and align with production schedules to minimize business impact.
Scope creep is the most common risk. Adding non-critical tasks after the scope freeze deadline leads to schedule overruns, budget blowouts, and resource fatigue. iFactory helps prevent scope creep with formal change management workflows.
Yes, iFactory provides bi-directional integration with SAP PM/EAM. Work orders created in iFactory sync to SAP, and vice versa. Cost postings flow to SAP FI/CO for financial tracking.
Yes, iFactory's mobile apps for iOS and Android provide full access to shutdown management features. Technicians can view assigned work orders, update task progress, capture photos, and complete tasks from anywhere — even offline.
From planning to execution, iFactory's shutdown management module gives you complete control over every turnaround. Track costs, manage critical paths, coordinate work orders, and ensure on-time, on-budget completion.