Total project planning: Integration of task analysis, safety analysis and optimisation techniques N. Balfe a,⇑ , M.C. Leva a , C. Ciarapica-Alunni a , S. O’Mahoney b a Centre for Innovative Human Systems, Trinity College Dublin, Ireland b ESB, Dublin, Ireland article info Article history: Received 30 June 2016 Received in revised form 19 September 2016 Accepted 25 October 2016 Available online xxxx Keywords: Project planning Risk assessment Optimisation Monte Carlo Task analysis Participatory planning abstract Safe and successful completion of complex projects in industrial environments requires careful planning and collaboration of different stakeholders. This paper presents the integration of three methods (task analysis, safety analysis, and project optimisation) to apply a holistic approach to complex project plan- ning. The attributes and limitations of the separate elements are discussed, and a case study applying the integrated methodology is presented. The results from the case studies indicate that significant benefits in terms of time, cost and safety can be achieved through the application of the integrated methodology. Ó 2016 Elsevier Ltd. All rights reserved. 1. Introduction The safe and successful completion of maintenance and over- haul procedures is dependent upon the collaboration of different departments and individuals, the clear planning of the work, and the availability of the required resources. For complex or rarely performed procedures, the competence and knowledge needed for planning and mitigating the risks associated with the project may be spread across different parts of the organisation. However, accessing and utilising this knowledge is critical for de-risking major projects and investments. Major projects, for example the delivery of the London Olympic Park, are increasingly placing value on the ability of suppliers and contractors to deliver projects with the highest levels of safety (Shiplee et al., 2011) and the criticality of safe performance of maintenance procedures is illustrated by major accidents such as Piper Alpha, Clapham Rail Disaster, and Texas Oil Refinery. However, Badri et al. (2012) state that project management is often deficient in integrating safety risks. In a study of 183 process industry major accidents, Okoh and Haugen (2014) found that 44% had a link to maintenance and of these, deficient planning/scheduling/fault diagnosis were a cause in 69%. Mainte- nance is also a factor in 15–20% of all occupational health and safety accidents, and 10–15% of all fatal accidents (OSHA, 2011). The need for safer maintenance must also be balanced with the business requirements for time and cost effective completion of maintenance activities. Previous research has focussed on identifying safety hazards as part of the project planning process, and has had some success in integrating the safety analysis with 4D models used to communi- cate and engage with project stakeholders (e.g. Benjaoran and Bhokha, 2010; Gerbec et al., 2016a). This paper extends such work by also incorporating uncertainty modelling using the Monte Carlo technique, giving stakeholders the ability to assess the impact of different resourcing choices on the project timescales and risk. This paper presents a methodology for the elicitation of the information required to fully plan a maintenance activity, assessing both safety and efficiency goals, using a participatory approach that harnesses the existing knowledge in the organisation and engages key stake- holders in planning activities to help ensure safe and timely com- pletion of activities. The results of a case study application of a maintenance overhaul procedure in an electricity generating sta- tion are also presented. The approach was developed under the scope of the TOSCA (Total Operations for Safety Critical Activities) project, which developed a set of principles, processes and tools to support Total Safety Management (TSM; Kontogiannis et al., 2016). TOSCA proposes the development of a Common Operational Pic- ture supported by four safety pillars: commitment in action, understanding risks and hazards, managing/treating risks, and http://dx.doi.org/10.1016/j.ssci.2016.10.014 0925-7535/Ó 2016 Elsevier Ltd. All rights reserved. ⇑ Corresponding author. E-mail address: balfen@tcd.ie (N. Balfe). Safety Science xxx (2016) xxx–xxx Contents lists available at ScienceDirect Safety Science journal homepage: www.elsevier.com/locate/ssci Please cite this article in press as: Balfe, N., et al. Total project planning: Integration of task analysis, safety analysis and optimisation techniques. Safety Sci. (2016), http://dx.doi.org/10.1016/j.ssci.2016.10.014