Preserve process manufacturing procedural knowledge: Yokogawa

To help process manufacturers preserve procedural knowledge, achieve production objectives, and meet health, safety and environmental regulatory requirements, Yokogawa launched Modular Procedural Automation (MPA).

02/09/2010


To help process manufacturers preserve procedural knowledge and achieveproduction objectives, while meeting health, safety and environmentalregulatory requirements, Yokogawa has announced the launch of ModularProcedural Automation (MPA). The announcement was made at the 14th Annual ARC Forum in Orlando on Feb. 8.

Yokogawa explained that procedural operations are used in all processes whether manually from standard operating procedures, prompted by a control system or fully automated. The key to the design of these procedures is the knowledge of the production operators. Operations can vary from shift to shift and site to site depending on the procedural knowledge of the operators. Good operators can provide significant operational savings to a manufacturer and also be a reliable interface when incidents arise. However, the most experienced operators in all process industries are starting to retire in large numbers leaving a procedural knowledge gap.

"Operational knowledge and the accompanying skill sets are leaving the workplace due to retirement, and consequently the availability of good operators to run process systems is diminishing," states Maurice Wilkins, vice president, Yokogawa IA global marketing center. "By applying MPA a company can preserve the knowledge of the best operator on his or her best day every day, which enables running a process in an optimal state." MPA is an open and modular approach to procedures that is production centric, not bound by systems and defines the right balance between manual, prompted, and automated procedures.

Brent Lilienthal, general manager North American services for Yokogawa, said, "Start-ups and shutdowns need specific skills and are one of the biggest sources of risk in a production process." Maurice Wilkins added that "effective grade changes and transitions can provide a source of competitive advantage for manufacturers if they are done the same way every time."

MPA starts with a consultative assessment of a site's procedural needs. A recommendation will then be made as to the best platform for the customer to achieve their desired result. Prompted procedures may be implemented on any control system using Exapilot, while fully automated procedures may need Centum VP solution or both.

"Customers have seen reductions of up to 98% of operator interactions during a polymer grade change and also a 69% reduction in crude switchover time in a refinery process," Lilienthal said. "We can't provide the knowledge that these experienced operators have, but we can provide an effective methodology to preserve that knowledge in MPA."

Also read:

- Closing the Skills Gap ; and

- Yokogawa VigilantPlant Services .

- Edited by Mark T. Hoske, editor in chief, Control Engineering, www.controleng.com.





No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Leaders Under 40 program features outstanding young people who are making a difference in manufacturing. View the 2013 Leaders here.
The new control room: It's got all the bells and whistles - and alarms, too; Remote maintenance; Specifying VFDs
2014 forecast issue: To serve and to manufacture - Veterans will bring skill and discipline to the plant floor if we can find a way to get them there.
2013 Top Plant: Lincoln Electric Company, Cleveland, Ohio
Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.

Bring focus to PLC programming: 5 things to avoid in putting your system together; Managing the DCS upgrade; PLM upgrade: a step-by-step approach
Balancing the bagging triangle; PID tuning improves process efficiency; Standardizing control room HMIs
Commissioning electrical systems in mission critical facilities; Anticipating the Smart Grid; Mitigating arc flash hazards in medium-voltage switchgear; Comparing generator sizing software

Annual Salary Survey

Participate in the 2013 Salary Survey

In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.

Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.

2012 Salary Survey Analysis

2012 Salary Survey Results

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.