Structuring Turnaround & Projects at Arlanxeo

LANXESS (now Arlanxeo) is a leading specialty chemicals company with sales of EUR 8.8 Billion in 2011 and currently around 17,100 employees in 31 countries. The company is represented at 48 production sites worldwide. The core business of LANXESS is the development, manufacturing and marketing of plastics, rubber, intermediates and specialty chemicals. In Belgium Lanxess has two legal entities with 3 sites in the Antwerp harbour area where rubber products and intermediates for plastics are produced.

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Project set up

At the Zwijndrecht location the Butyl Rubber Business Unit (BTR) produces high-quality butyl and halo butyl rubbers for the tire and rubber industry. In 2009 the Zwijndrecht plant was awarded a large investment which had severe impact on the planned 2011 Turnaround.

To prepare the Turnaround 2011 Lanxess requested PDM:

  • To analyze the current Way of Working with regard to the turnarounds; to identify existing good practices in relation to structures and processes
  • To define and implement optimizations and provide operational planning & scheduling support
  • To use the results for further initiation of improvements in Turnaround management within Lanxess

Integration of turnaround and project into one programme

Turnaround

1. Maintenance Inspection items
2. Stop related project works (Tie-ins)

Projects

3. IPP: Integrated Pilot Plant for Butyl
4. FSFL: Full scale Finishing Line Projects
5. Projects Poly
6. Project Halo-templates on which the future processes could be designed were used for the purpose.

Deliverables

  • Defined project execution plan
  • Defined Integrated Schedule
  • Defined Contracting plan
  • Performed Risk Management Workshop with key personal where risks were identified and mitigated
  • Designed and implemented progress reporting system
  • Performed Interface management between maintenance, projects, planning and scheduling
  • Defined Scope management process
  • Defined and implemented optimised work permit process

Mr. Walraven
Managing Director, Lanxess

Throughout the whole process PDM has been involved as TA management and operational support partner to Lanxess for planning, construction coordination and supervision, and during this time they have been critical to Lanxess Rubber with respect to our challenges and practices.


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