Synchronising Planning, Agility, and Safety: A Novel Integrated Framework for Turnaround Maintenance Execution

Turnaround Maintenance (TAM) in petrochemical facilities is characterised by high schedule pressure, intensive resource concurrency, and stringent safety constraints arising from simultaneous operations (SIMOPS) that must be taken in parallel. While existing scheduling approaches focus primarily on planning-phase optimisation, executionphase control remains a critical source of delays and resource-access conflicts. This study proposes an execution-control framework designed to enhance schedule robustness and decision-making effectiveness during TAM execution. The framework integrates constraint-based control mechanisms, short-interval coordination, and SIMOPS-informed decision rules to manage execution uncertainty in dense work environments. Validation is conducted through a structured workshop-based simulation and a live petrochemical shutdown case study, enabling comparative assessment against conventional execution practices. The results signify improved conflict resolution, significantly higher decision quality without increased latency, and enhanced schedule resilience under disruption, evidenced by a 9.6% baseline schedule compression and a 26-hour reduction in actual shutdown duration compared to historical benchmarks. The findings demonstrate that execution-focused control, systematically integrated with Lean, Agile, and spatial constraints, provides measurable benefits beyond traditional planning-centric methods. The study contributes a practical, field-validated approach to TAM execution and control management.