Enhancing Labour Productivity in Petrochemical Construction and Maintenance Projects

Abstract

Construction labour is a significant cost factor for petrochemical plant owners and their contractors. Enhancing labour productivity is therefore indispensable for the petrochemical industry in order to achieve sustainable development. Considering the variety of projects undertaken by this industry (i.e. construction and more particularly, maintenance and shutdowns/turnarounds), there is a lack of standard methods for assessing labour productivity. This generates a need for developing productivity assessment practices suitable for all project types. This paper presents solutions for labour productivity improvement based on a study conducted at various petrochemical plants.The study developed and implemented a modified Activity Analysis method suitable for the site conditions, with a focus on maintenance activities and shutdown/turnaround projects, which were rarely considered on previous productivity assessment approaches. Conducted over two cycles, this study assessed the current labour productivity, identified barriers, and analysed the efficacy of solutions implemented to mitigate these barriers. The aggregate direct work percentage was found to have increased in the second cycle. The analysis of labour productivity through Activity Analysis in maintenance and shutdown/turnaround projects is a key contribution of this study. The findings provide a basis for assessing and benchmarking labour productivity in the petrochemical industry.

Study on Labor Productivity Improvement Based on Situational Awareness and Improved Value Stream Mapping

“…In order to raise the direct work rate of the workers, Sriya Muralidhara et al [47] offered a number of improvement solutions for the non-value-added activities of workers on site. Neve [48] discovered through a case study that using lean tools in construction projects could decrease non-value-added activity and raise labor productivity.…”

Enhancing Turnaround Maintenance in Process Plants through On-Stream Phased Array Corrosion Mapping: A Review

“…Turning the spotlight to plant shutdown turnaround, Muralidharan et al [7] introduced an activity-analysis approach tailored to site conditions. Their analysis revealed that turnaround personnel expended substantial waiting time beyond direct work, whether for permits, instructions, materials, or QA/QC inspections.…”

“…This section also encapsulates the challenges researchers face in TAM and introduces diverse methodologies for enhancing TAM systems. Techniques such as assessment tools for optimization [6,7], questionnaire surveys [8,9], software aid development, and Risk-based Inspection methods [10,11] have emerged as effective approaches in this context.…”

Activity sampling in the construction industry: a review and research agenda

“…(1) Productive work, value-adding work, effective work, direct work CII (2010) proposed seven activity categories: direct work, preparatory work, material handling, tools and equipment, travel, personal and waiting. Several studies directly adopted the CII activity list to analyse labour time utilisation (Gouett et al, 2011;Liu and Golparvar-Fard, 2015a, b;Sheikh et al, 2017;Siriwardana et al, 2017), and some studies further modified the activity list to suit the site conditions or study needs (Karunarathna et al, 2019;Muralidharan et al, 2018). Apart from that, Wandahl and Skovbogaard (2017) also proposed seven activity categories, Production, Talking, Preparation, Transport, Walking, Gone and waiting, which were further adopted by Neve et al (2022) and Neve and Wandahl (2018).…”

“…, 2017), and some studies further modified the activity list to suit the site conditions or study needs (Karunarathna et al. , 2019; Muralidharan et al. , 2018).…”