Facilities routinely conduct operator rounds to keep plants running safely and smoothly. However, this practice is now being challenged with the retirement of experienced operators (loss of invaluable knowledge and experience), advanced technology (more capabilities, requiring further training) and increased operator responsibility (operators now performing maintenance tasks). Thus, facilities are now tasked with streamlining operator activities, providing operators with the knowledge and experience to respond to field conditions and keeping operators updated on improvements in processes and technology.
PinnacleART’s operator rounds implementation addresses these challenges and provides significant return on investment through improved reliability and availability. Our experts utilize Reliability Centered Maintenance (RCM) principles and processes to optimize operator surveillance duties based on reliability/ availability improvement, product quality, safety and environmental factors. These tasks typically include daily surveillance activities (e.g. check for leaks, verify acceptable oil level), documentation of local gauge readings for trending, routine swapping of spare pumps, and other tasks that are not managed by the Computerized Maintenance Management Systems (CMMS).
Click here to read our article, “The Importance of Operator Driven Reliability (ODR) in Process Manufacturing Facilities,” by PinnacleART RCM Reliability Specialist Brent Davis.
PinnacleART’s operator rounds solution focuses on the following elements:
Round Optimization: By utilizing RCM principles and processes, PinnacleART optimizes operator rounds by helping operators know what symptoms to look for, in order to capture failures before they occur.
Operator Response: PinnacleART experts, using RCM principles, work with your plant personnel to identify actions to be taken by the operator, based on conditions they may find during their rounds.
System Training and Configuration: PinnacleART can provide system assessments of software/hardware solutions, training on how to enter the rounds, and development of key performance indicators (KPIs) and dashboards.
Sustainability: PinnacleART works with local plant resources to define, document and implement sustainability programs to ensure your operator rounds stay focused on taking readings that provide the greatest long-term value.
By delivering on these four aspects, PinnacleART’s operator rounds solution helps clients achieve:
Avoidance of unplanned failures through early detection
Enhanced facility reliability
Increased asset availability
Optimized maintenance costs
Standardized operator tasks
Improved operator performance and efficiency
Potential optimized asset life span through early detection of improper operating conditions