The Biggest Threats to Turnaround Schedules and How to Overcome Them

In the world of industrial turnarounds, every minute counts. Planned outages are costly enough on their own, but unplanned delays can quickly multiply the expense, impacting production schedules, workforce efficiency, and overall profitability. Across the industry, three issues consistently rise to the top as the biggest causes of turnaround delays: unplanned discoveries, late material delivery due to supply chain disruptions, and lack of communication.

Navigating Surprises in the Field

Unplanned discoveries, or “scope creep,” are nearly unavoidable in complex repair and maintenance work. Once crews start breaking into equipment, they often find additional repairs or replacements that weren’t part of the original scope. Suddenly, these are components that need to be sourced in a matter of hours, not days, to keep the job moving.

Material logistics can compound the problem. Even if a replacement part is manufactured quickly, it still has to reach the site. Weight limits, freight restrictions, customs clearance, and even the dimensions of a plane’s cargo door can create unexpected delays. In many cases, balancing the need for speed with cost-effective shipping becomes its own challenge.

Staying Ahead of Supply Disruptions

Supply chain stability plays a central role in keeping projects on track. Even the best planning can be derailed by factors outside of a manufacturer’s control, such as market fluctuations that drive up prices overnight, raw material shortages that delay production, or geopolitical shifts that disrupt established shipping lanes. These factors can ripple through the supply chain quickly, affecting availability long before a part is ever manufactured. Manufacturers need to anticipate these changes well before they affect a project, ensuring the right materials are on hand when they’re needed.

That’s why proactive planning is essential. Manufacturers must understand customer needs and monitor supply trends, build strong relationships with multiple suppliers, and maintain contingency options for critical materials. Anticipating potential bottlenecks before they surface allows teams to secure the right materials in advance, preventing last-minute scrambles that slow down production. In industries where timing is everything, a stable, resilient supply chain isn’t just an advantage, it’s a necessity.

Aligning Teams to Avoid Costly Delays

When multiple vendors, suppliers, and plant teams are involved, communication is a critical factor. From the production floor to the shipping dock to the end users on-site, it’s essential to keep everyone aligned on order status, potential delays, and delivery schedules. Without clear communication, even a small disruption can escalate into hours or even days of lost productivity.

Without that steady flow of information, small issues can snowball. A minor shipping delay that could have been mitigated turns into a missed shift. Miscommunication about part availability leads to crews waiting on standby with nothing to install. In complex projects, time lost isn’t just inconvenient, it can mean significant cost overruns, missed deadlines, and strained relationships. Strong communication isn’t just good practice; it’s the difference between a smooth job and a costly disruption.

Turning Turnaround Challenges into Success Stories

To ensure a successful turnaround, solving these problems should start long before the turnaround begins. That’s why Lamons works closely with facilities on pre-planning, reviewing unit scopes, identifying material needs, and securing those materials in advance. This includes turnaround trailers or consignment trailers, on-site, stocked “mini warehouses” where critical gaskets, bolts, and hoses are available the moment they’re needed.

When unplanned discoveries happen, we’re ready to respond. Our TruFast process allows field measurements to be turned into production drawings almost instantly, expediting manufacturing without sacrificing precision. Our account managers and engineers regularly go on-site to take those measurements themselves, ensuring accuracy from the start.

Strategically located branches across the country mean we can service facilities locally, reducing lead times and increasing responsiveness. When speed is critical, our logistics team works with the site to determine the fastest, most efficient, and cost-effective shipping method, whether that’s same-day freight, overnight air, or local delivery.

We also maintain a robust supply chain, with multiple global sourcing options and a close eye on market trends. This allows us to anticipate shortages and adjust purchasing before it impacts our customers. Our vendor-managed inventory (VMI) programs keep essential materials on-hand at customer facilities year-round, minimizing the risk of downtime from supply disruptions.

Above all, we focus on clear, consistent communication. We schedule project meetings to review open orders and make sure plant teams know exactly what’s on order, what’s been delivered, and where there may be potential delays. This transparency allows both sides to pivot quickly, keeping turnarounds on schedule.

In the world of turnarounds, every decision, every part, and every hour matters. The difference between a smooth, cost-efficient outage and an expensive, drawn-out delay often comes down to preparation, agility, and collaboration. By combining strategic planning, responsive manufacturing, robust supply chain management, and clear communication, Lamons helps facilities minimize risk and maximize uptime. Turnarounds will always bring their share of surprises, but with the right partner, those surprises don’t have to turn into setbacks. Whether it’s planning months in advance or solving problems in the middle of a shutdown, Lamons approaches every turnaround with the same priority: on-time, on-quality, every time.