Operations Management Solution – Driving Safety and Profitability One Shift at a Time

| Advanced Solutions – Digital Transformation | 2020 |
© Yokogawa Corporation of America
Driving safety and profitability one shift at a time
Operations Management Solution

Host and Panelist
1
MARLA MARTINEZ
Marketing Specialist
Yokogawa Corporation of America
Sugarland, TX
marla.martinez@yokogawa.com
www.yokogawa.com/us

Presenter
4
TAYLOR SCHULER
Advanced Solutions, Digital Transformation & Safety
Business Development Leader
Yokogawa Corporation of America
Sugarland, TX
taylor.schuler@yokogawa.com
Taylor has had a 20-year career in digitally transforming companies in the Oil and Gas Industry. He is experienced in
designing, implementing, and taking to market digital twins with a focus on safety and continuous improvement towards
profitability. He takes pride in simplifying complex solutions from the board room to the shop floor. He is passionate about
all things “Tennessee Volunteers” from his Nuclear Engineering degree achieved the last time the Vols won the National
Championship in football.

Let’s Flatten the Curve!
3

Today’s Agenda
4
1. Published data
2. The challenge
3. Our solution
4. Live demonstration
5. Value add review
6. Next steps
201515

5
Unplanned Shutdowns & Slowdowns
36% Equipment
42% People
22% Process
Distribution of Unscheduled
Shutdowns and Slowdowns
Operator faults and errors can lead to unwanted
downtime and production losses. The chart below
shows that the major reason for plant downtime is due to
human error followed by equipment failures.
Average Dollar Loss per Major Incident by Cause
$0 $20 $40 $60 $80 $100
Malice Activity
Design Error
Natural Hazard
Process Upset
Unknown
Operational Error
Mechanical Failure
M
Source: J&H Marsh & McLennon, Inc.

6
Shift Turnover Effectiveness
Shift
handover
5%
Other
activities
95%
Operations Time
Shift
handover
40%
Other
activities
60%
Plant Incidents (Total)
Source: NPRA 2009 National Safety Conference.
Incoming
Shift
Outgoing
Shift
Discussion
Questioning
Clarification

7
Example Shift Handover Incidents
Piper Alpha
1988 - Poor shift management, communication and
unstructured shift handover processes resulted in a loss of
containment, explosion and permanent loss of the entire Oil
Platform and 167 fatalities
Texas City
2005 - Poor shift management, communication and
unstructured shift handover processes combined with poor
adherence to procedures and other systemic failures resulted in a
loss of containment, explosion and 15 fatalities
Buncefield
2005 – An instrument failure compounded by poor cross facility shift
management, communication and unstructured shift handover
processes resulted in a loss of containment, explosion and permanent
loss of 20 storage tanks and 60 Mil gallons of fuel products

8
The Shift Handover Challenge – Simple View
1. Prepare Handover 2. Review Documents 3. Information Exachange 4. Sign-off Handover
Shift
Supervisor
Approves
Outgoing Shift
Walk Down
Workstation
Incoming Shift
Checklist
Approved
Outgoing & Incoming Shift Supervisor
Workstation and
Operator Logs
Equipment Status
Log
Lock-out Tag-out
Log
Alarm Summary
Management of
Change
Operating Limits
History & Actions
Handover Checklistmore+ +more

9
Typical Workflow and Timing
Routine
Maintenance
WorkProcess
SHEWorkProcesses:
•ProcessSafetyManagement
•PersonalSafetyManagement
Production
Planningand
Scheduling
FieldOperator
SH 1: SHIFT CLOSE OUT
Final field walk down
• Changes in equipment conditions.
• Equipment status data
• Visual observation of seal leakage
• Consolidate the abnormality points and Identify
maintenance work request based on equipment
condition
Prepare shift
handover report
Safety
Observations
PTW Status
Equipment
Status
Shift Handover
Report
PannelOperator
Final console walk down
• Alarm status
• Laboratory data/analysis
• Key control process variables
• Emissions off specification
Prepare shift
handover report
Lab Analysis
Shift Handover
Report
• Patrol and complete PDA check
• Record in logbook area for following
shift & follow up actions
• Key in maintenance work orders
• Prepare for shift manning record
Maintenance
Work Order
Foreman
• Compile issues for each process area
• Validate field operator log book
• Inform Shift Supervisor of any
outstanding Maintenance work
Update status of work list:
• Maintenance request list
• HSE Observations
• LCR housekeeping
ShiftSupervisor
Production Report to
AV, SM, DSM, Maint.
Planning and HSE
Prepare
production report
Equipment Report to
Shift Superintendent
• Conduct a field visit
• Key in production and
equipment status
Consolidate List of
Maintenance Work
Request
Identify gaps
between standards
and actual conditions
Identify Gaps/ deviations
between daily operating
instructions and scheduling
vs. actual conditions
Conduct a Plant walk down
FieldOperator
SH 2: SHIFT TEAM HANDOVER
Both off going and on
coming jointly conduct a
review of log book and
discuss current status
PanelOperator
Conduct a console walk down
including alarms and ESD
Report to Shift
Supervisor
Foreman Both off going and on
Shift
SupervisorShiftSupervisor
Shift Hand over Report to
Plant Manager
Routine
Maintenance
WorkProcess
SHEWork
Processes
Production
Planningand
Scheduling
Individual Shift
Handover
Individual Shift
Handover
Individual Shift
Handover
Individual Shift
Handover
Report to Shift
Foreman
Shift Hand over Report to
Shift Supervisor
SHEWorkProcesses:
FieldOperator
SH 3: SHIFT TEAM PLANNING
Daily Work
Instructions from
Foreman
PannelOperator
Daily Operating
instructions from
Shift Supervisor
ForemanShiftSupervisor
Update previous
Shift information
Shift Team
handover meeting
Update previous
Shift information
Generate
Work Plan
Shift Team
handover meeting
(Lead)
Request for specific technical support:
• Process
• Reliability
Daily
Production plan
Daily Operating
instructions
Prepare shift
work instructions
Daily
Maintenance Plan
Daily Operating
instructions
Daily Safety
instructions
Reviews
Production Plan
Meeting with
Plant Manager
Daily
Maintenance Plan
Daily Operating
instructions
Daily Safety
instructions
Daily
Maintenance plan
MOC Process
Is equipment
under warranty?
Specify “Need
by” date
Convert to WO
and generates
job plans
Is Work Order
an Emergency?
Apply Risk
Assessment
Contact vendorConvert Work
Request to Work
Order
RoutineMaintenance
WorkProcess
Conduct Job Safety Analysis (JSA)
Convert Work
Request to Work
Order
Permit to
work issued
Generate Daily Safety specific
instructions
Safety
Observations
Daily Safety
instructions
• Define process gap source and
improvement actions
• Update Schedule
• Generate Daily
Operating instructions
Daily Operating
instructions
Production Planning and Scheduling
Shift Team
handover meeting
(By Phone/Video)
• Alarm review
• Inform sample
requirements
Daily meeting to
agree on :
• Risk rank and
prioritise
• Is a MOC
Required?
Y
N
Production
Planningand
Scheduling
FieldOperator
Near miss and
Incident report
PannelOperatorForemanRoutineMaintenance
WorkProcess
SH 4: SHIFT TEAM EXECUTION
Conduct regular operational field rounds:
• Routine product sampling
• PDA Patrol and data recording
• Monitor specific parameters of major
equipment
• Supervise contractor work
• Prepare Equipment for Maintenance (as required)
• Manage Abnormal situations (as required)
• Communicate with Panel Operator (as required)
• Optimize process variables within Daily Production Plan guidelines
• Regularly track stream qualities and lab data
• Monitor key process variables and trends
• Monitor and respond to process alarms
• Communicate with Field Operator /Foreman / Shift Supervisor (as required)
Lab Analysis
Permit to work
(PTW) to contractor
Tool/equipment and
work allocation for
contractor stewardship
Toolbox
meeting
• Coordinate Panel and Field Operations
• Patrol the unit and check PDA data
• Inspection contractor work
• Communicate with Field Operator/Panel Operator/Shift Supervisor
Permit to work
(PTW) status
ShiftSupervisor
Field Inspection to check :
• Contractor work
• Equipment repair status
• HSE conditions
Report to Plant
Manager
Hand over to
operations
Execute and
complete Work Order
Permit to work
(PTW) issue
Near miss and
Incident report
SHEWorkProcesses:
Monthly safety observation
report with risk ranking and
action plan
• Follow up / Audit safety observations
• Conduct regular unit safety walk downs
• Prepare incident report (as need it)
• Consolidate Safety Observations
• Risk rank the safety observations
and define action plan
Conduct regular equipment care duties:
• Lubrication/seal barrier levels
• Turbine trip mechanism checks
• Heater firing Status/problems
• Equipment vibration monitoring
Production Planning and
Scheduling input
• Monitor production plan execution
• Monitor process optimization
• Monitor product quality
• Review critical process and equipment alarms
Production
Planningand
Scheduling
30 minutes 15 minutes 30 minutes 8 or 12 hour shift cycle
Shift Team
Effectiveness
Standard™

10
Our Operations Management Solution (OM)

11
Out-of-the-box: Shift Handover RolesShiftTeamEffectivenessStandard™

12
Out-of-the-box: Dashboards by RolesShiftTeamEffectivenessStandard™

Bijuraj Pandiyath
Solution Demonstrator
Solution Architect
Operations Management
Yokogawa - Singapore
A quick look into our solution…
13

14
Live Demonstration
Add the video

15
Value Proposition

Benefits Summary
Digitalization
enables
structuring
previously
unusable data
16
Aid safe
operations by
reducing
communication
gaps due to
human fatigue
Enhance
human
collaboration
using sharable
content
Eliminate silo
operations
and improves
traceability

Benefits Summary
Improves
decision
making by real
time information
sharing
17
Creates
operational
knowledge
base and best
practices
supporting root
cause analysis
Automatic consolidation and reporting
of information to improve operational
efficiency
 30-minute reduction per manager per day by
streamlining report and KPI generation
 30-minute reduction per shift handover
(shift supervisors, panel operators, staff
reports, etc.)
 Save days per year with alerts, reminders,
and query able data to quickly take action

Benefits Summary
Prevent loss due to
operational errors by
establishing control of
work procedures
18
Eliminate incidents
due to operational
errors by providing
guidance for task
execution and
standard checklist /
operating procedures

19
Questions & Answers
Next Steps
Thank you for your time

Operations Management Solution – Driving Safety and Profitability One Shift at a Time

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Operations Management Solution – Driving Safety and Profitability One Shift at a Time