Improving Operational Integrity
First-hand production and automation experience enable UCDS to help clients change the culture and improve operational integrity including a substantial reduction in operational costs. Our method is centered around human performance, human factors, and specifically understanding the responsibilities of the operator. We work very closely with both engineering, automation, and the operators to identify why their support systems like the alarms are not improving performance and which user interfaces and behavior factors are hindering operator performance. We do this by identifying gaps in the Conduct of Operations and developing management systems that support a high level of Operational Discipline.
Developing Our Models
In conclusion, UCDS is a control room and field operations – human performance company. Below, you can see our control room model starts with measuring workload and ends with a control room design that integrates each step into the final 3D rendering of the control room. Our Field Operation model specifically addresses workload, task management, dives deep into your conduct of operations (site standards, policies, and guidelines), and then looks at how well operators understand their roles, responsibilities, and their effectiveness at performing their tasks. This is a deep dive into operational discipline. Ensuring every task is performed correctly, every time, even when nobody is watching. During this process, we help you develop a Best in Class “Conduct of Operations & Operational Discipline” program.
“Survey respondents acknowledged the potential for operators to significantly influence plant performance, as well as ongoing need to improve measures that would make them more effective in their jobs. When asked to what extent better prepared operator could positively influence key performance metrics, respondents placed significant accountability in the hands of the operators. Operators not only have a big impact on availability, equipment damage and personnel safety, but can play a big role in quality, environmental and economic performance as well. But an overwhelming majority of survey respondents also confirmed the increasing scope of board operator responsibilities, with more than three-fourths indicating a growing workload.”
– Keith Larson, ed., “Operator Interface—State of the Technology Report,” Control, April 2015.
(Also See Doug Rothenberg’s book Situation Management for Process Control)
You have an older production facility with control hardware from different vendors, ranging from pneumatic to distributed control. An upgrade of DCS equipment is necessary to increase reliability, reduce maintenance costs and implement advanced control, but you are unsure of what new equipment purchases will best suit your needs.
Your plant is split into multiple control rooms, each serving one or two units. The buildings are old, some are in poor condition, and they all place your operators too close to the unit in case of fire, explosion, or toxic release. Your safety personnel are saying you must spend a significant amount of money to replace, relocate or upgrade the buildings.
Benchmarking surveys indicate a surplus of operators. Upper management is considering first quarter staff cuts, but it is unclear how to decrease worker population without compromising safety.
It falls to you to find cost-effective strategies, justify a positive payout, and secure approval for expenditures.
