Advansoft ODM Application: Plant Operator Driven Reliability (ODR)

Advansoft ODM Application:
Plant Operator Driven Reliability (ODR)
Why Operator Driven Reliability (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 corrosions, 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 enable operators to drive reliability?
Advansoft’s ODM solution is a Plant Mobile Data Management and Decision Support solution that helps to
facilitate and integrate the manually collected inspection, observation or surveillance data, by replacing the manual
log sheets with the latest technology of mobile devices and ODM software application. ODM enables:
Reliability team to design and standardize the field inspection work processes
The knowledge of experienced reliability engineers who build the work process and corrective action rules to be
retained and continuously improved based on best practices
Field operators to enter field data and their observations digitally, accurately, thoroughly and consistently
Field operators to be alerted to abnormal conditions and advised with Corrective Action Guide 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
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The ODM - Operator Driven Reliability Process Flow
Management/Planner
(Supervisor/Reliability/Safety officer)
Field Workforce
- Create/Maintain data collection route
- Create/Manage task
- Maintain CAG rules/knowledge
(Operator/Inspector/Engineer)
Synchronize
task list
Continuous
Improvement
Review Inspection Task List
- Notified with daily & ad-hoc inspection task
- Alerted to any overdue or missed task
Record Process & Machine Data
- Digitally record process data,
and rounds inspections
(with RFID/barcode)
- Manually trigger alarm to alert supervisor
- Business System
(SAP/Maximo/etc)
Upload
data
Data Review & Analysis
- Supervisor to review and acknowledge field data
and alarm status
- Field workforce KPI analysis
- Generate management report
- Machine health information is accessible easily
to reliability team for analysis and actions (e.g.
review and approve work request)
Alerts & Feedback
- Prompt operator for abnormal conditions
- Historical data from previous shift is at
fingertips for trend analysis
- Encourage operator to report feedback
on the abnormalities (comments, record
voice, sketches note & image capturing)
Corrective Actions
- Prompt immediate corrective actions and
additional ad-hoc task or data collection
- Initiation of work request
THE RESULT / BENEFITS
Better visualization of assets conditions
Plant ODR inspection data and feedback from field
personnel are well documented in electronic form,
make it very easy to be accessed and analyzed
Shift supervisor & reliability team are more alerts to
abnormal data trends
Increasing management review of collected data
Improve field operations
Field data is prioritized easily from the alarm and
are rectified quickly
Change of operators’ behavior 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
Reduced assets unplanned downtime
Leveraging operators to perform simple preventive
maintenance and predictive maintenance check prior to
skilled maintenance personnel to troubleshoot more
complex machine problems
Early detection of abnormal machinery health
conditions facilities more time for root cause analysis
and maintenance, contributing to increase machine
availability
Root cause analysis is supported by machinery
health data, collected frequently by operators
Optimizing human resources
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
For more information about ODM product and services, please contact Advansoft’s ODM solutions sales department
at +603 80769905 or visit our website at http://www.myadvansoft.com/odm.html
www.myadvansoft.com