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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.
Advanced Operating Graphics
Plant Safety and Productivity Improvements Realized by Mental Model Based PCS Graphics
Yokogawa provides a full range of HMI design consulting capabilities to assist understanding of the current situation compared to industry standards (ISA101) and peer performance; combined with our experience to drive improvement within production facilities.
Based on our proven performance, knowledge, and experience, we offer consulting services for graphic design of process control system to improve productivity, safety, and the work condition of your plants.
Customer Challenge
Developing An Effective HMI to Mitigate Risk
Safe and efficient operations rely on operations staff being able to quickly identify potential process deviations before the situation reaches an unsafe or undesirable production condition.
Based on the experience and research at Yokogawa we have identified that the root cause of this is not just in operator training; but it revolves around having an operations environment that is aligned with the operators mental model and work processes.
Our Solutions
Combining Industrial Design and Operations Knowledge
Yokogawa clearly understands customers’ challenges and has developed significant expertise in operations HMI development. Based on this existing expertise Yokogawa has developed a standardized method for development of site specific HMI design guidelines and a collection of template graphic objects and standards that we are now offering globally.
Advanced Operating Graphics (AOG) is a consulting service provided by Yokogawa to redesign PCS graphics based on human factors engineering and Operations engineering. It is this combination production operations and human factors that ensures that the resulting design brings together the physical production process with the way operators visualise this in their mind.
As a result AOG provides intuitive situation awareness through ergonomic design, primarily focused on layout and design based on operating environment in compliance with ISA101; whilst providing efficient decision making by capturing operational know-how from experienced operators.
Key Features
- Operator Mental Modelling to understand how operators perceive the process
- Ergonomically designed graphics provided by a team of human factors engineers.
- Operational, task-based graphics provided by operations engineers.
- Safety and Productivity KPI (Key Performance Indicator) graphics.
- Full compliance with ISA101 standards
Customer Benefits
Reduce Operator Workload and Mental Fatigue, Allowing Time and Energy to be Focused on High-Level Plant Operations
INPEX Corporation (INPEX) is Japan's biggest oil and gas development company and is involved in all aspects of this business, from research to exploration, production, and sales. Redesign of user interface dramatically improved operations at the companies plant in Niigata. The company enjoyed the following major benefits:
- Shortened operation monitoring cycle
- Timely identification of abnormal conditions
- Fewer operator errors
- Reduced operator workload / eye fatigue
- Improved transfer of skills and expertise
- Increased motivation to improve operations
Read the full success story here: http://www.yokogawa.com/success/oilgas/suc-inpex.htm
Interviews
Dr. Maurice Wilkins - executive advisor at Yokogawa speaks with Alastair Greener from the Business Reporter at the Daily Telegraph and shares his thoughts on Process plant operators, automation and how they need to work together in a crisis.
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