Operational Excellence

Honeywell’s solutions are centered on important aspects that address the operational tasks required to attain Operational Excellence.  An ideal Operational Excellence model focuses on the management structure and policies down to the processes involved in operating a process facility. Honeywell’s solutions are the tools that enable the work processes to be accomplished in order to meet specific safety, reliability and efficiency goals. Many factors affect Operation Excellence.  A key to achieving Operational Excellence is to know the limits of your process and to operate within those limits.  Overall management of goals, objectives, scheduling and tracking contribute to how effectively your plant operates within boundaries. Honeywell can deploy an extensive set of tools and services to help your production facility achieve its Operational Excellence goals, including improved safety, increased efficiency and operation within limits. Alignment and Awareness – understanding of common goals from management to operations Workcenter dashboards provide users with unsurpassed visibility and secure interaction with their process and business data.  Workcenter facilitates employees at all levels to make collaborative decisions and work as a team across the value chain. Operating Instructions is a software application used to manage the daily operating plan and targets for process plants, mines and mills, and improves coordination between departments in a uniform, structured way.  A clearer understanding of the operating plan helps process plants run more effectively, and achieve the plan faster and more precisely. Operate Correctly – operator training and procedures UniSim Operations Suite, Honeywell’s Operator Training Simulator, helps prepare operators for initial and sustained plant operation.  Not only can this help reduce potential incidents, but well-trained personnel react more quickly and diffuse process situations before incidents occur.  Experience has proven that simulators train new hires more quickly and efficiently than traditional methods. Procedural Operations automates procedures to reduce the variability associated with performing a task providing obvious efficiency improvements and eliminating potential safety risks.  Honeywell understands the importance of this capability and delivers this functionality as part of the default capabilities of its Experion Process Knowledge System. Honeywell’s Alarm Configuration Manager provides appropriate alarm help information to the operator when requested.  Per recommendations by organizations such as the ASM® Consortium, details about the cause, recommended responses and potential consequences of an alarm should be defined and presented to the operator when required. Operate in Design Envelope – define the limits and operate within them Honeywell’s Alarm Configuration Manager goes beyond simply managing alarms.  The Master Boundary Database captures and manages all sources of limits derived from Hazard and Operability Analysis (HAZOP), Process Hazard Analysis (PHA), safety system trip settings, pressure relief and level limits, risk-based inspection data, reliability-centered maintenance data and more.  These limits can be mapped to alarms that are presented to the operator for immediate action to keep the process in the operating envelope.  Honeywell’s Operations Monitoring software can also systematically monitor performance against targets and limits, and highlights problem areas. Console operators using Experion Station have extensive alarm management capabilities at their disposal to help them operate within the design envelope.  The advanced interface, with functions such as Alarm Shelving, helps operators focus on the necessary alarms they need to act upon to keep a process operating within limits.  Honeywell’s Advanced Alarm Management suite of products goes even further to help create an effective alarm system.  Honeywell’s involvement with the ASM Consortium allows all projects to be implemented according to guidelines created by this industry-leading organization. Operator Surveillance – situational awareness for a more effective operator Field Advisor is designed to provide an operations excellence solution for the mobile field worker. When combined with the balance of Honeywell’s operations excellence solutions, the entire operations team, including field workers, work toward a common goal of operating the plant within safe limits using consistent best practices.  Experion has powerful functionality that can be deployed when creating the operator interface.  Honeywell’s human factor experts analyze operator tasks to fully understand the scope required for an operator interface.  They can then deploy tools such as the HMIWeb Solution Pack shape library to create an interface that is effective and meets the intent of guidelines such as those published by the ASM Consortium. Digital Video Manager (DVM) addresses video surveillance, security and industrial plant operational requirements.  DVM is a powerful solution that can help enhance plant productivity by providing vision of the process that could not be previously viewed. Mobile Station is a wireless mobile productivity solution that extends access to critical process information, historical data, displays and other key functions to the field user, relaying control system information to remote users where and when needed. Several Experion Station node types are available. Each has powerful features for a variety of applications, and all share a common user interface utilizing HMIWeb technology.  All Experion Station types can be mixed on any system to achieve the most functionally powerful and cost-effective operator interface available. Operations Tasks – manage the wide array of tasks that must occur to keep the plant running Honeywell’s wide array of tools help manage the routine operations tasks from routine maintenance (changing filters, for example) to annual operator training.  Operator Logbook is a good example of one of these tools.  This software application is used to keep an electronic record of what happens during a shift.  It is ideally suited to help with a smooth shift handover, and to enable an operations department to coordinate its own activities.  An accurate record of what occurred on shift helps process plants run more effectively, reduces errors and improves effectiveness. Solve Specific Problems – specific problems can be solved with data and metrics available Well-run plants still encounter problems at times. Honeywell’s varied products and solutions help support work processes by capturing the knowledge gained from working the problem and using it to improve future operations. Track Performance – make problems visible for quick resolution Operations Monitoring systematically monitors process plant performance against targets and limits, and highlights problem areas.  It also helps to determine causes of downtime and production inefficiencies.  By studying operations history, plant staff can more efficiently manage and control operations. KPI Manager helps define and track key performance indicators.  When a deviation is detected, KPI Manager triggers a work process for corrective action and continuous improvement. Honeywell’s Biz Calc and Advanced Formula Manager applications are designed to meet the calculation needs of a process organization.  These solutions provide an easy-to-use tool for users to configure, manage, execute and troubleshoot calculations, as well as to interconnect with an ERP system to allow validation and closing of data in periodic or fiscal intervals.  BizCalc’s integrated design with Honeywell’s Uniformance® PHD enables real-time measurement data in a meaningful business format to be delivered to all stakeholders. Rich reporting is available within the context of the tools used to support the various work processes identified.  In the boundary management solution, Honeywell’s Alarm and Event Analysis provides a wide range of standard and custom reporting capabilities to enable continuous improvement.  Honeywell’s Operations Monitoring also provides a range of standard and customizable reports to help understand deviations and their economic impact when striving for continuous improvement of process operations.