Operations Excellence - ASM Consortium
Operations Excellence - ASM Consortium
Operations Excellence - ASM Consortium
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Honeywell Users Group 2009<br />
Return on Imagination<br />
Chris Stearns<br />
<strong>Operations</strong> <strong>Excellence</strong>
<strong>Operations</strong> <strong>Excellence</strong><br />
What is OE?<br />
Why OE?<br />
How?<br />
What’s it<br />
look like?<br />
2
What is <strong>Operations</strong> <strong>Excellence</strong>?<br />
Efficiency<br />
Reliability<br />
Safe<br />
<strong>Operations</strong><br />
Management<br />
of Change<br />
Product<br />
Quality<br />
Environmental<br />
3
What is <strong>Operations</strong> <strong>Excellence</strong>?<br />
DEFINE<br />
MEASURE<br />
CONTROL<br />
ANALYZE<br />
IMPROVE<br />
4
Why <strong>Operations</strong> <strong>Excellence</strong>?<br />
Increased Capacity 5 %<br />
Improved capacity utilization 3 %<br />
Decreased unscheduled shutdowns<br />
and slowdowns<br />
50 %<br />
Improved productivity 10 %<br />
Reduced fixed cost 15 %<br />
Improved energy utilization 5 %<br />
Gillard, C. F. "Creating plant operating excellence with measurable results." HYDROCARBON PROCESSING Apr. 2001: 57+.<br />
5
Why <strong>Operations</strong> <strong>Excellence</strong>?<br />
“For an average-sized refinery,<br />
these improvements should<br />
deliver an economic benefit of<br />
$25 million/year”<br />
Gillard, C. F. "Creating plant operating excellence with measurable results." HYDROCARBON PROCESSING Apr. 2001: 57+.<br />
6
Why <strong>Operations</strong> <strong>Excellence</strong>?<br />
“…ensure<br />
effective<br />
management of<br />
abnormal<br />
situations.”<br />
7
Why <strong>Operations</strong> <strong>Excellence</strong>?<br />
“the design of OEMS fully<br />
addresses, and in some<br />
respects goes beyond, the<br />
requirements of ISO 14001<br />
and OSHAS 18001”<br />
“Safety and environmental performance<br />
within Chevron’s operations has improved<br />
since the deployment of OEMS.”<br />
8
Why <strong>Operations</strong> <strong>Excellence</strong>?<br />
Kosaric, Namik; Petronas.<br />
Defect Elimination<br />
Conference. 2005.<br />
9
How Does Honeywell Support OE?<br />
Management Structure and Policy<br />
Change Management and Compliance<br />
Applications and Support Tools<br />
Work Processes<br />
Alignment<br />
and<br />
Awareness<br />
Operate<br />
Correctly<br />
Operate in<br />
Design<br />
Envelope<br />
Operator<br />
Surveillance<br />
<strong>Operations</strong><br />
Tasks<br />
Solve Specific<br />
Problems<br />
Track<br />
Performance<br />
Gillard, C. F. "Creating plant operating excellence with measurable results." HYDROCARBON PROCESSING Apr. 2001: 57+.<br />
10
How Does Honeywell Support OE?<br />
• Dashboards (Workcenter)<br />
• Operating Targets/Instructions (Operating Instructions)<br />
• Training Simulators (UniSim <strong>Operations</strong>)<br />
• Procedures<br />
• Alarm Help<br />
• Boundary Management<br />
• Alarm Management<br />
• IntelaTrac PKS<br />
• <strong>ASM</strong> Effective Operator Interface<br />
• Logbook<br />
• <strong>Operations</strong> Monitoring<br />
• KPI Manager<br />
• Yield Accounting<br />
• Reports<br />
Alignment<br />
and<br />
Awareness<br />
Operate<br />
Correctly<br />
Operate in<br />
Design<br />
Envelope<br />
Operator<br />
Surveillance<br />
<strong>Operations</strong><br />
Tasks<br />
Solve Specific<br />
Problems<br />
Track<br />
Performance<br />
11
Operating in the Design Envelope Today<br />
The Road Ahead.<br />
Your Driver.<br />
The Result.<br />
The Process.<br />
The Operator.<br />
The Result.<br />
12
How Does Honeywell Support OE?<br />
• Dashboards (Workcenter)<br />
• Operating Targets/Instructions (Operating Instructions)<br />
• Training Simulators (UniSim <strong>Operations</strong>)<br />
• Procedures<br />
• Alarm Help<br />
• Boundary Management<br />
• Alarm Management<br />
• IntelaTrac PKS<br />
• <strong>ASM</strong> Effective Operator Interface<br />
• Logbook<br />
• <strong>Operations</strong> Monitoring<br />
• KPI Manager<br />
• Yield Accounting<br />
• Reports<br />
Alignment<br />
and<br />
Awareness<br />
Operate<br />
Correctly<br />
Operate in<br />
Design<br />
Envelope<br />
Operator<br />
Surveillance<br />
<strong>Operations</strong><br />
Tasks<br />
Solve Specific<br />
Problems<br />
Track<br />
Performance<br />
13
Current Practice – No Alarm, No Problem<br />
One problem in an<br />
otherwise perfect<br />
day<br />
All problems<br />
resolved, nothing<br />
else to report<br />
alarm limit<br />
process<br />
14
Know Your Limits<br />
Planned operation<br />
beyond alarm<br />
limit<br />
Why is the alarm<br />
limit here,<br />
anyway?<br />
Planning target<br />
changed but<br />
nobody knew<br />
alarm limit<br />
process<br />
planning target<br />
Planning targets<br />
not met<br />
On plan, but in<br />
trouble….<br />
15
Know Your Limits<br />
Violating<br />
equipment<br />
parameters<br />
Increased<br />
fouling until<br />
now<br />
Violating<br />
equipment<br />
parameters<br />
process<br />
planning target<br />
alarm limit<br />
excessive<br />
fouling<br />
economic<br />
feasibility<br />
Economic<br />
operation<br />
economic<br />
feasibility<br />
excessive<br />
fouling<br />
16
17<br />
Boundary Management
18<br />
Operating Instructions
19<br />
Operator Surveillance
Now, let’s go for that drive….<br />
The Road Ahead.<br />
Your Driver.<br />
The Result.<br />
The Process.<br />
The Operator.<br />
The Result.<br />
20
OE Addresses Industry Challenges<br />
Safety<br />
Protect People, Assets<br />
and Process<br />
Reliability<br />
Improve Availability<br />
Reduce Downtime<br />
Efficiency<br />
Improve Productivity<br />
Reduce Cost<br />
Billions lost per year<br />
in Petrochem Industry<br />
Millions lost per year<br />
due to unplanned<br />
production losses<br />
Fewer people<br />
can make better<br />
decisions, faster<br />
21
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