Audience: project managers, site engineers, ops leads
Goal: deliver works in occupied/operational facilities with zero surprises, zero harm, and minimal downtime.

Why sequencing matters

• Production and customer operations cannot stop.
• Safety risks increase with shared routes, plant and people.
• Dust/noise/odour can contaminate product or void warranties.
• Unplanned isolations jeopardise business continuity and insurance.

Principles to run by

1. Safety leads the programme. No permit, no work.
2. Operations first. Black-out dates and change freezes trump convenience.
3. Single truth. One look-ahead, one set of drawings, one comms thread.
4. Protect interfaces. Movement, utilities and information flow.
5. Evidence everything. RAMS briefed, permits logged, QA photographed.

Five-stage playbook

1) Discovery & constraints capture

• Map departments, people flows, FLT routes, fire egress, hygiene zones.
• Log black-out periods, shift patterns, planned outages, deliveries, audits.
• Confirm noise/dust limits, cleanliness classes, hot-work rules.
• Agree a Change Control process (who approves, how fast).

2) Zoning & segregation

• Physical barriers (solid where dust-sensitive), negative/positive pressure as needed.
• Mark safe walkways, FLT aisles, fire routes; add access control.
• Dedicated laydown, waste and charging areas.
• Daily housekeeping standard (photos at start/finish).

3) Isolation & changeover strategy

• Electrical/mechanical/process isolations planned with LOTO; create a register.
• Temporary supplies/bypasses where continuity is required.
• Pre-commissioning and changeover rehearsals (“dry runs”).
• Agree revert plan if changeover fails (timeboxed go/no-go).

4) Works windows & micro-sequencing

• Use nights/weekends or micro-windows between batches.
• Break tasks into short, testable increments with recovery time.
• Example (packaging line upgrade):
  1. Pre-build skid off-line → FAT complete
  2. Isolation & disconnect (02:00–03:00)
  3. Remove old conveyor (03:00–04:00)
  4. Lift/position new module (04:00–05:00)
  5. Services hook-up (05:00–06:00)
  6. Cold commission & safety checks (06:00–07:00)
  7. Trial run with product (07:00–07:30)
  8. Contingency/revert window (07:30–08:00)

5) Interfaces, logistics & permits

• Booked delivery slots and defined routes; spotters for shared areas.
• Lift plans, TM plans, waste routes; no ad-hoc movements.
• Permit board: hot works, roof access, MEWP, excavation, confined space.
• Daily permit review at start-up meeting.

Quality & HSE built into the sequence

• ITP with hold points tied to windows: isolation proved, fixings torqued, guards fit, interlocks tested.
• Pre-use checks for access/plant; LOLER/PUWER docs on file.
• Hygiene sign-off and cleaning records before handback.

Communication cadence (keep it light, keep it regular)

• Weekly: coordination meeting with operations (review next 2–6 weeks).
• Daily: 10-minute start-up at the workface (permits, people, plant, plan).
• Change notices: simple one-pager—what/when/where, risks, mitigations, contacts.
• Single point of contact on both sides.

Two-Week Look-Ahead (snapshot):

• Windows confirmed ✔
• Permits pre-approved (draft) ✔
• Drawings/IFC issue ✔
• Plant & access booked ✔
• Risk hot-spots + contingencies listed ✔

KPIs that actually help

• Window hit rate % (planned vs achieved)
• Unplanned disruption count (target: zero)
• Permit compliance % (briefed, signed, closed)
• Defects at handback (target: zero blockers)
• Near-miss reporting (quality over quantity)

Red flags—stop and escalate

• Permit missing or controls not in place.
• Overrun threatens start of operations.
• Unapproved route/plant change.
• Unexpected utility/service behaviour.
• Dust/noise/odour exceeding limits or any contamination.
  Action: make safe → notify ops lead → follow revert plan.

Pocket checklist (A5)

• Latest drawings & single schedule
• Black-out dates logged
• Zones & routes marked, barriers erected
• RAMS briefed; permits ready
• LOTO kit & isolation plan
• Delivery slots booked; laydown clear
• ITP hold points known to crew
• Housekeeping standard agreed
• Handback criteria & sign-off names

Photos that prove control

• Barriers & signage in place
• Isolation tags & readings
• Fixings with torque witness marks
• Guarding/interlocks tests
• Cleanliness checks at handback
• Permit board at start/end of shift

Final word

In live facilities, sequencing is risk control. Break the work into safe, testable chunks; protect interfaces; keep comms boringly predictable. Do that and you’ll finish on time with operations still smiling.

Want editable look-ahead, permit board, and handback templates? Email [email protected] and we’ll send a pack aligned to your scope.