Operations Management System

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Key areas for Operational Excellence Transformation

Operational Excellence Transformation is Yokogawa and KBC’s co-innovated portfolio of solutions and services.We provides comprehensive solutions for business automation in all four areas using consulting and digital technology.

Operational Risk Management

Yokogawa's Operational Risk Management deals with managing safety, health and environmental risks on both individual and process levels in a reliable and risk-free manner. It involves the end-to-end process of designing, visualizing and orchestrating plant production and business systems.

Key Operational Competencies in Operational Risk Management

  • Process Safety Management: Maintain License to Operate, preserve Business Reputation, and create value by utilizing and adhering to operating integrity processes to prevent loss of containment or catastrophic loss
  • Personal Safety Management: Protect human assets by providing safe practices to improve behaviour and culture
  • Environmental Management: Provide processes to protect the environment through operating integrity, and ensure compliance with environmental, regulatory and/or internal requirements
  • Community Relations: Define and establish processes and protocols to communicate and implement emergency response plans, and enhance interactions in the community
  • HSSE Reporting and Compliance: Assure visibility and achievement of HSSE goals and compliance requirements, by monitoring, learning and improving continuously through processes, initiatives and KPIs
  • Plant Protocols and Security: Provide processes and strategies to protect assets and infrastructure from threats, and control access to vulnerable processes and equipment

By combining Yokogawa’s product portfolio and KBC’s consulting services, we provide our customers best practices and domain knowledge that empower them to improve their operations, as well as a digital platform that supports such activities and initiatives. Our Operational Risk Management scope does not only cover partial improvements in the organization, but also optimizations in plant operations to achieve continuously improving safety, reliability and operability.

 

·Supply Chain Optimization

- Optimize management of supply, whether oil in the ground or feedstocks for a refinery or chemical asset, in light of product market demands. This provides operators with the agility to take full advantage of market conditions.
·Asset Operations and Optimization
- Optimize the potential of physical assets, by pushing throughput and maximizing the production of the highest value products, whilst minimizing variable costs such as energy.
- Deliver small and large capex projects, on time and on budget, to deliver growth and meet environmental requirements.
·Asset Management and Integrity
- Confidently ensure asset reliability and availability, whilst controlling maintenance costs. This assures the asset always meets expectations and is always available to capitalize on short term market opportunities. 


Operations Management System

Operations Dashboard

Operations Management solution helps to ensure Safe, Reliable and Efficient plant operations and regulatory compliance by digitization of information related to key Operations Management Practices. This results in improved productivity through standardized work practices, streamlined processes, plus improved communications and coordination across departments.

Major Operations Management solution benefits includes the following:

  • Consistent, structured and integrated approach to plant operations management
  • Improved retention of expert knowledge and lessons learnt
  • Fast and efficient change management of operations and maintenance processes
  • High productivity and reduced cost of operations and maintenance activities
  • Providing better integration of all operations’ critical applications and systems
  • Enforced standard operating procedures and practices
  • Improved collaboration and inter-department communications
  • Ensure statutory compliance to Health, Safety, Security and Environment
  • Real-time access to critical information across plants for improved and informed decision makings

 

Operations Management solution functionalities are modular in nature and include the following modules:

Logbook

  • Multiple log types with view layout and data set
  • Association of the log with plant hierarchy
  • Link the log to Work Instruction


Work Instruction

  • Multiple work instruction types with view layout and data set
  • Work instruction template which provides preconfigured data automatically upon instruction creation
  • Configurable Excel based checklist configured upon template engineering and updated upon Work Instruction execution


Management of Change

  • Single view to record and monitor statuses of plant wide MOCs
  • Structured and configurable MOC workflow (Initiation to Close Out) completely adaptable to customer’s best practices


Incident Management

  • Track and manage plant wide incidents and non-compliances related to health, safety, security, environment and production incidents e.g. equipment trips, outages etc.
  • Structured and configurable Incident Management workflow (Reporting to Close Out) completely adaptable to customer’s best practices


Permit to Work

  • Track and manage plant wide PTWs, Isolation and de-isolations/lock out tag out (LOTO) activities
  • Structured and configurable PTW workflow completely adaptable to customer’s best practices


Shift Handover

  • Auto generation of Shift Handover reports based on shift configuration per roles and plant locations/ departments
  • Auto compilation of shift report based on shift data for log, instructions, process data, trends and their excursions, overrides, incident management and permits to work information etc.

All of the above Operations Management solution modules have rich user experience with the key features below:

  • Rich text data entry
  • Color coded Status and Priority identification
  • Personalized/configurable list view preference
  • Alert notifications for new records using auto refresh, highlighting overdue (display) or pending actions (email)
  • Personalized/Configurable information filtering using multiple criteria

All above modules are accessible from one web-browser window. This single window access allows users to view the portal window to access all the operation critical information that are composed of Logbook, Work Instruction, Management of Change, Incident Management, Permit to Work and Shift Handover. Users can easily navigate to different modules using the navigation button.

 

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