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OPERATOR ROUND CHECK
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- Periodically plant process and equipment health inspection
- Automate inspection data recording and inspection report summary generation
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OPERATOR DRIVEN RELIABILITY / EQUIPMENT BASIC CARE
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- Emphasizes operator involvement and ownership of equipment performance
- Expanding and engaging the knowledge, skills, and abilities of the front line people (operators)
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EX INSPECTION & MAINTENANCE FOR ELECTRICAL EQUIPMENT
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- Ensure explosion-proof electrical equipment is inspected periodically and comply with ATEX/IECEX standards
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SAFETY EQUIPMENT INSPECTION & MAINTENANCE
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- Ensure safety equipment is inspected periodically and comply with fire & safety regulations
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SAFETY OBSERVATIONS & AUDITS
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- Safety assessment and monitoring of unsafe actions and conditions
- Increasing safety awareness in the workplace
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Operator Driven Reliability (ODR)
Why ODR?
Production operators are valuable resources to plant reliability-based asset management strategy, as they are the closest person to the machine and are usually the first to detect even the smallest changes in process conditions and machinery health, such as abnormal readings, leaks, signs of corrosion, weird noise, excessive vibration and heat.
Unfortunately, most of the time their observations are not reported at all and no remedial action is taken quickly. Because of this, sometimes it will be too late to effect changes that could reduce equipment break down, prevent stop of production and safety incidents.
ODR is one of the best practices that empower operators to be part of the plant reliability strategy where people, processes and technology is integrated. This will bring positive change to the organization’s culture that encourages the operations, maintenance, and reliability departments to communicate and work together more effectively towards mutual reliability goals.
How ODM enables operators to drive reliability?
- Field operators to enter field data and their observations digitally, accurately, thoroughly and consistently, to be alerted to abnormal conditions and advised with Corrective Action Guide rules by the experienced reliability engineers who build the work process and corrective action rules
- Deliver prioritized field operators findings and alerts to reliability team for review and analysis
- Link operations and maintenance department with up-to-date inspection task to operator and feedback / work request / notification initiated by operator
- Reliability team to design and standardize the field inspection work processes and improve staffs behaviour from “react” to “anticipate”, and etc.
What are ODR Benefits ?
Better visualization of asset conditions & Reduced asset unplanned downtime
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- ODR plant inspection data and feedback from field staff documented in electronic form, making it very easy to access and analyze and mitigate the use of time in making an inspection
- Early detection of abnormal machinery health conditions facilities more time for root cause analysis and maintenance, contributing to increase machine availability
- Shift supervisor & reliability team are more alerts to abnormal data trends and Increasing management review of collected data.
Improve field operation
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- Field data is prioritized easily from the alarm and are rectified quickly
- Change of operators’ behaviour from anticipate to react
- Increase operator involvement proactively will help plant to achieve reliability goals.
- Common platform and better flow of information between both operations and maintenance department will increase communication, enhance knowledge and teamwork.
Optimizing human resources
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- Reliability department utilizes the current resources of operations department to collect ODR observation data efficiently, without increasing additional man power
- Saving valuable time of reliability engineer in data compilation and analysis
Plant Safety Observation
ODM provides a mobile solution that:
- Enable safety officer to design and standardize the safety observation data collection
- Enable field personnel to enter field data digitally via a mobile device, store them and synchronized with the centralized database
- Safety level assessment and monitoring of unsafe areas
- Deliver prioritized information and alert safety officers
- Retain the knowledge of the workers who build the work process
- Increase the level of safety in the field by identifying abnormal situations
The Challenges
Safety observation program is always needed and has been implemented in most of the plant nowadays in order to help them to prevent injuries, by helping people to talk to each other about safety and increasing safety awareness among the staffs of the plant. With such program in place, the real costs of accidents can be measured and controlled.
In order to achieve this, safety observation card or log sheet was assigned to respective departments and personnel to record down their observation and feedback about the plant safety conditions. The data from the cards was later being entered into spreadsheets for monitoring, assessment and further analysis.
Unfortunately, due to the limited resources in safety department nowadays, sometimes these data will remain inside the cards or log sheets as it was too time consuming to be put into digital form. As a result, most of the time the up to date plant safety level can only be accessed once or twice a year. Worst still, it may not be accessed at all!
What are the Benefits ?
Better visualization of plant safety conditions
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- Plant safety observation data and feedback from field personnel are well documented in electronic form, make it very easy to be accessed and analyzed.
- Increasing management review of collected data
- Unsafe area is prioritized easily from the alarm system
Improve safety and environmental compliance
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- Better flow of information increases the efficiency and effectiveness of safety officers
- Safety officers are more alert to plant’s unsafe areas
- Unsafe area and sections are easily identified for remedial actions
- Safety report (e.g. safety level, unsafe conditions, etc) is generated easily
Optimizing human resources
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- Safety department utilizes the resources of all departments to collect safety observation data efficiently, without increasing additional man power
- Saving valuable time of safety officer in data compilation and analysis.
