Progressive Plan International Inc., headquartered in Western Canada, is a forward-thinking consultancy committed to supporting complex projects across both public and private sectors. Building on our strong foundation in industrial shutdowns, turnarounds, and outages (STOs), we have expanded our expertise to provide advanced project management solutions for a wide range of industries.

At Progressive Plan, we empower organizations through cutting-edge technologies, including predictive team performance solutions via Match Connector, all while remaining agnostic to specific technologies. Our core philosophy is grounded in delivering optimized solutions that empower, innovate, and enhance operational performance.

We collaborate with clients, general contractors, and specialty vendors to foster strategic partnerships that prioritize shared success. Our dedication to mentorship, best practices, and dynamic scheduling methodologies ensures our clients achieve efficient, cost-effective, and successful project outcomes.

Industrial shutdowns, turnaround events, and outages (STOs) are pivotal events for maintenance and upgrades in asset-intensive industries, such as power generation, oil and gas, petrochemical, and refining sectors. These processes are intricate and frequently result in substantial delays, cost overruns, and schedule disruptions. Turnarounds often suffer from fragmented scoping, inconsistent planning, and poor execution alignment across stakeholders. These issues are further compounded by constrained timelines, contractor misalignment, and under-utilized scheduling tools.

Recent studies and internal industry data*, highlight the urgency for reform:

- Over 80% of turnarounds exceed budget by more than 10%

- 82% fail to meet performance objectives

- Nearly 50% of industrial incidents occur during shutdowns or maintenance outages

- Despite 98% documenting lessons learned, only 42% actively implement them

Delays in decision-making, late contractor engagement, scope creep, and schedule rigidity continue to challenge operational excellence. Addressing these issues requires a comprehensive, structured, and dynamic approach to turnaround management—one that prioritizes planning maturity, scope integration, and technology-enabled execution support.

The challenges identified in the plant turnaround process underscore the necessity for comprehensive planning, efficient data management, and robust coordination. A comprehensive approach, incorporating meticulous planning and scheduling, robust risk management, effective communication, and strategic use of technology, is crucial. By anticipating potential issues and implementing proactive measures, these practices ensure safer, more efficient, and cost-effective turnarounds, mitigating risks associated with delays, cost overruns, and schedule disruptions across various industrial sectors.

* Data Sources

1) TA Cook and Solomon Associates (2019)

2) Cleopatra STO Survey (2024)

Our approach addresses the recurring challenges faced in industrial Shutdowns, Turnarounds, and Outages (STOs)—including schedule overruns, fragmented planning, and underutilized tools—by offering an integrated solution focused on five core pillars:

1) Practical Management of Plant Turnarounds (PMPT): Structured training and implementation support to define the turnaround premise, align roles and responsibilities, and embed readiness and gate-based assurance milestones.

2) Plan2Plan (P2P) Playbook Development: Co-development of a milestone-based planning framework that aligns all stakeholders—Operations, Capital, Maintenance, and Contractors—around shared deliverables, timelines, and compliance metrics.

3) Dynamic Scheduling Methodology (DSM): Training and mentorship in DSM to establish systemzed, logic-driven, float-optimized, and execution-responsive schedules. This includes schedule audit frameworks and resource-loaded planning structures to enhance scheduling maturity.

4) AI-Driven Schedule Optimization with ALICE Core: Deployment of ALICE Core to enable parametric optioneering and scenario analysis. DSM serves as the foundation to ensure high-quality inputs (“Gold In, Gold Out”), delivering scalable, AI-enhanced planning options.

5) Work Process Reviews and Assurance Activities: Independent analysis of current turnaround workflows, schedule health checks, scope challenge facilitation (RBWS and J-Factor), and readiness reviews aligned with Plan2Plan milestones.

The scope of work is structured across delivery phases, each building capability while reinforcing long-term planning discipline and internal ownership. This modular structure ensures alignment with turnaround planning cycles and organizational structure.

By combining best-in-class methodologies with collaborative delivery, Progressive Plan aims to help clients institutionalize smarter turnaround practices—enhancing performance, reducing risk, and enabling consistent execution excellence.