How do you achieve Operational Readiness in Greenfield Industrial Projects?

Operational Readiness (OR) is a crucial aspect of any greenfield industrial project, ensuring that new facilities and operations start up smoothly and deliver expected performance from day one. Effective OR planning minimizes risks, reduces costs, and accelerates time-to-production. This article provides a comprehensive framework for implementing OR in greenfield sites based on industry best practices and standards. 

1. Key Challenges of Greenfield Operational Readiness

Implementing OR in greenfield projects presents unique challenges: 

• Lack of Existing Infrastructure: Unlike brownfield projects, greenfield sites start from scratch, requiring a comprehensive development strategy for all systems, processes, and resources. 
• Resource Allocation and Training: Hiring and training personnel from the ground up is critical to ensure that the workforce is equipped to handle new systems and technologies. 
• Alignment with Project Phases: Integrating OR activities into each phase of the project lifecycle (from pre-feasibility to commissioning) is essential to avoid misalignment between project teams and operational teams. 

2. Stages of Operational Readiness Implementation

2.1. Initiation and Feasibility Validation (Concept and Pre-Feasibility Phase)

The initiation and feasibility phase focuses on validating operational requirements from the start of the project. This includes evaluating the project’s viability, identifying potential challenges, and confirming that all operational requirements are addressed in the early planning stages. Key activities include: 

• Establishing the initial OR team: Defining roles and responsibilities to ensure alignment with project objectives. 
• Conducting initial risk assessments: Identifying potential risks to the project and developing preliminary mitigation strategies. 
• Developing a high-level OR plan: Defining the operational philosophy, establishing the organizational structure, and outlining initial resource requirements. 

This foundational step lays the groundwork for subsequent activities by aligning the project’s objectives with operational capabilities from the outset. 

2.2. Risk Analysis and Execution Planning (Feasibility and Execution Planning)

During this phase, the focus shifts to detailed planning of OR activities. It includes developing strategies to maximize equipment performance and managing operational risks. Key steps include: 

•  Developing the asset management strategy: Maximizing equipment performance throughout its lifecycle. 
• Identifying and managing operational risks: Using structured frameworks like HAZOP (Hazard and Operability Study) to evaluate and mitigate risks. 
• Creating a comprehensive training plan: Designing training programs for all operational personnel to ensure familiarity with processes and systems. 

This phase ensures that execution plans are aligned with operational requirements and industry standards. 

2.3. Design Integration and Equipment Pre-Testing

The design integration and pre-testing phase focus on ensuring that all equipment meets performance criteria and integrates well with other system components. Activities in this phase include:

•  Verifying design integration: Ensuring that all systems are designed and integrated to work harmoniously once operational.
• Pre-testing equipment: Ensuring equipment compatibility with existing systems and compliance with performance criteria. 

Successful design integration ensures that all parts of the facility will function together cohesively. 

2.4. Construction, Installation, and Quality Testing

Continuous OR reviews during the construction and installation phases ensure adherence to quality standards. Rigorous testing and validation processes are conducted to confirm that every aspect of the facility is operationally sound. Key steps include: 

• Systematic quality checks: Verifying that all components and systems function correctly. 
• Updating standard operating procedures (SOPs): Developing final documents such as SOPs, emergency procedures, and maintenance schedules. 

2.5. Execution and Commissioning

This phase involves putting the OR plan into action, with active participation from the operational team in commissioning and acceptance testing. This facilitates effective knowledge transfer and ensures that all stakeholders are prepared for operations. Key activities include:

• Involving the operational team: Engaging the team in all commissioning phases to facilitate ownership and knowledge transfer.
• Finalizing operational documentation: Including SOPs, emergency procedures, and maintenance schedules.

2.6. Operational Readiness Completion

All OR deliverables must be completed before the start of commissioning activities, including: 

• Finalizing staffing: Ensuring that all operational positions are filled and trained. 
• Completing the master data set: Ensuring that all technical, historical, and procedural information is centralized and accessible. 
• Conducting readiness audits: Performing OR audits to confirm that all operational requirements are met. 

2.7. Commissioning, Handover, and Inauguration

The final stages include comprehensive commissioning activities and the formal handover of the facility to the operational team. Structured operational frameworks and resource engagements ensure that the facility is fully functional and ready for full-scale operations. The formal handover and inauguration mark the successful completion of the OR process.

 2.8. Post-Implementation and Continuous Improvement

Post-implementation, OR plays a key role in evaluating operational adjustments to confirm that all changes achieve the expected outcomes. This phase includes continuous monitoring and assessment to maintain operational efficiency and identify opportunities for continuous improvement.

3. Best Practices for Implementing Operational Readiness

• Early Involvement of Operations Teams : Engage operational teams early in the project lifecycle to provide insights into operational requirements and potential risks. 
• Develop a Comprehensive OR Plan: The OR plan should cover all aspects of asset management, human resources, safety, and compliance, ensuring alignment with the overall project objectives. 
• Align with Industry Standards and Frameworks: Utilize established frameworks such as ISO 55000 for asset management to guide the OR strategy and ensure best practices are followed. 
• Focus on Training and Knowledge Transfer: Ensure that operational staff are thoroughly trained and familiar with the systems and processes before the facility is handed over. 

Conclusion

Operational Readiness is a structured, multi-disciplinary approach that ensures the seamless transition of greenfield projects from construction to full operation. By focusing on early planning, human capital development, asset management, and risk mitigation, organizations can achieve smooth start-ups, reduce operational risks, and optimize the long-term value of their investments.

Erwan Lecuyer,
Spartakus Technologies
[email protected]