PLANT MANAGEMENT
Augmented Manual Procedures (AMP) is a procedural automation solution that reduces the risk of costly mistakes
The AMP software converts paper- based SOPs into a digital format that operates operating on devices such as as smartphones and tablets
interruptions, equipment damage and even injury. Given the stakes – coupled with
initiatives such as Industry 4.0 to further increase the level of automation at plants – many processors are now seeking ways to transform manual, paper-based SOPs into the interactive, digital documents that are fully integrated and synchronised with existing plant control and other enterprise computing systems. In doing so, processors expect a variety of benefits in plant safety, quality, and efficiency.
SAFETY, QUALITY, BETTER DATA When it comes to safety, eliminating the human error that can occur using paper-based SOPs is critical. According to ARC industry reports, human error is the primary cause in 42% of abnormal events, and a secondary contributing cause in over 65% of the cases. Human error causes more financial losses and unscheduled shutdowns or slowdowns than any other root cause. Te financial losses stemming from a single incident can exceed US$75 million (according to professional services
firm, Marsh & McLennan) to say nothing of the risks to plant personnel. Te digital approach enables plants to keep procedures clear, compliant and up-to-date and reduces the likelihood that human error triggers abnormal events that could compromise worker safety. Digital, connected SOPs are also a more effective way to transfer industry know-how across generations and geography. From a quality and efficiency perspective, ensuring operators carry out up-to-date SOPs also has a direct impact on process and product quality, while minimising scrap, waste and the need to troubleshoot. A more integrated digital approach also
allows top management access to superior analytics. Industrial analytics can not only help reduce costs but also drive future revenue growth when used to provide insight into upgrading existing products, changing the business model of existing products and creating new business models.
DIGITAL TRANSFORMATION OF MANUAL PROCEDURES Although there are a number of products that can be used to generate digital SOPs and store them electronically (paper-on- glass), few have the interconnectivity to facilitate real-time interaction between
the executing SOPs and the plant control system. Some DCS providers are also offering proprietary solutions, but digital SOPs should ideally be flexible, centralised and designed to communicate with any connected system.
A platform-independent architecture using open standards and protocols enables machines and operators to better collaborate. In this vein, the ability to execute procedures can make it possible to connect with key control systems to collect information and coordinate actions, embedding scripts can extend functionality with logic including accessing real-time information from other databases and systems. Tis approach provides an equipment operator with all the relevant information needed to complete work efficiently and can be easier and more intuitive to use. One example is Augmented Manual
Procedures (AMP) from NovaTech, a software that ensures accurate SOP execution, along with validation of manual tasks, and comprehensive information capture/sharing. Te software converts paper-based
SOPs into a digital format, capable of operating on a wide range of hardware such as smartphones, PCs and tablets. Te information is displayed as an operator- friendly checklist, and accessories such as
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