SAP PM Turnaround Readiness Checklist (Free)

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12 critical items still open - these are the highest-risk gaps.

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Scope and governance

Scope is frozen by a documented date and changes go through a change control boardCRITICALEvery work item has a notification or order in SAP PM before freezeCRITICALShutdown budget is approved and cost collectors or WBS elements existCritical path and duration are agreed with operationsRoles, escalation path and daily meeting cadence are publishedMandatory inspections and statutory items are confirmed in scopeCRITICAL

Orders and planning in SAP

All orders have operations, work centers, planned hours and durationsCRITICALA common planning marker or shutdown field links orders to this eventDependencies between jobs are loaded, for example in a network or scheduling toolWork center capacity versus demand reviewed by trade (CM01 or similar)CRITICALOrders are costed and checked against the budgetTask lists are used where standard jobs exist, to cut planning timeLong-lead jobs have a planned release date well before shutdown

Materials and spares

Component reservations exist on every order that needs partsCRITICALAvailability check run; shortages have a purchase requisition or POCRITICALVendor confirmed delivery dates for all long-lead itemsStaging area and kit lists prepared and labeled by orderSpecial tools, cranes and rentals bookedReturns process for unused parts agreed

Contractors and people

Contractor contracts and service entry sheets are set up for the eventCRITICALContractor safety induction and competence checks completeCRITICALCrew rosters and overtime approvals are in placeWork center and personnel assignments loaded for confirmationsAccommodation, access badges and transport arranged

Safety, permits and isolation

Work permits and isolation certificates are prepared for high-risk jobsCRITICALIsolation plan reviewed and lockout points identifiedCRITICALEmergency response plan covers the additional headcountEnvironmental and waste handling plans approvedJob safety analyses completed for non-routine tasks

Execution and close-out

Daily progress is confirmed in SAP and compared to planCRITICALProcess for scope additions and emergent work is agreedTechnical completion and settlement rules defined for ordersStart-up and commissioning checklist is readyLessons learned review is scheduled

Aim to close every critical item before scope freeze plus agreed lead time. Any open critical item is a risk to the shutdown start or duration and should have an owner and a date.

Shutdown readiness dashboard

Optional expert review of tracking shutdown order, material and capacity readiness directly from SAP.

Optional. The tool and every export work without this. No spam.

How to use it

Work through the groups with the planning team about eight to twelve weeks before the shutdown, then again at the freeze date and the final week. Tick items as complete and mark any critical open item with an owner. Export the list to PDF or Excel for the readiness review meeting, and keep one copy per shutdown event.

Run the checklist at three gates: early, at freeze and at final readiness.
Assign each unchecked item an owner and a date.
Treat critical items as gate conditions.

What the checklist covers

Scope and governance make sure the work is defined and controlled. The SAP planning group checks that every job is an order with operations, hours and a work center, and that capacity is feasible. Materials confirm reservations and availability. Contractors and safety groups cover the people and permit side. Execution and close-out prepare for confirmations, settlement and lessons learned.

Common failures

The usual causes of an overrun are late scope, missing reservations, unplanned permits and contractors who cannot book time. Many sites also find that capacity by trade is overloaded in week one. Run a capacity check by trade early, rather than assuming overtime will cover it. Use standard task lists for repeat jobs to shorten planning.

Freeze scope and honour the freeze with a change board.
Check parts before the shutdown, not during it.
Settle order costs promptly to compare with the budget.

Frequently Asked Questions

How far ahead should shutdown planning start?

Large turnarounds often start planning six to twelve months ahead, with scope freeze eight to twelve weeks before start. Smaller shutdowns can use shorter windows, but long-lead parts still set the pace.

How do I group shutdown orders in SAP PM?

Many sites use a common field such as a planner group, a user status, a system condition, a shared project or a network, so that reports can filter all orders for the event. Choose one convention and apply it consistently.

What is a critical item here?

A critical item is one whose failure can delay the shutdown start, extend its duration or create a safety risk. Treat each as a gate condition for the readiness review.

Does this replace a scheduling tool?

No. Many plants use a dedicated scheduling tool for the critical path and use SAP PM for orders, materials and costs. This list checks that both are aligned.

If you want shutdown readiness measured live from SAP orders, reservations and capacity, Netray can build a dashboard on your own infrastructure.

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SAP PM Shutdown and Turnaround Readiness Checklist