Look, Listen and Feel on Digital Format through Field Assistant

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We will remember COVID-19 for many years. Businesses were impacted severely, and a huge financial pressure was felt by several countries. Under these circumstances it was difficult to run plants which require people-to-people close communication.

On August 4th, 2020, more than 2000 tonnes of ammonium nitrate stored at Beirut's port caused an explosion and more than 200 people died. Don’t you think that a simple inspection and timely information system could have avoided that explosion?

If we look at this situation from a risk assessment perspective, then I would say most of the plants were ill-equipped to mitigate or avoid such risks. Operators can run plants efficiently with reduced staff if they plan well in advance. The solution is not only useful in a crisis, but also helpful under normal conditions.

Field Assistant

The digital transformation of process plant field activities, such as an operator’s round, basic equipment care, predictive maintenance, etc. can benefit from using a digital Field Assistant. It improves safety, reliability, and efficiency. In addition, it helps teams to communicate seamlessly while working inside their individual departments or across the organization.

The Field Assistant consists of a simple on-premise server, web client, and tablet applications, that connects seamlessly with the server for operator ease.

Major Features

1.     Digitalized SOP with assistant features and its compliance check evidence

2.     Smart document reference anytime at a field

3.     Standardized communication scheme with digitalized data collected from field

4.     Digitalized data can be utilized in conjunction with process data or other plant data

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Success Story

Yokogawa Electric Corporation (Yokogawa) developed the solution used by UBE Corporation Europe (UCE). The UCE plant in Castellón, Spain, produces nylon 6 for food packaging films and chemical fertilizers for the European, North and South American, and African markets.

Customer Challenge

UCE wanted to improve their plant maintenance efficiency. To achieve their goal, they wanted to use the Total Productive Maintenance (TPM) method. However, they sought guidance on how to use the TPM method efficiently.

The Pain Point

They were using a paper-based maintenance report during patrol. One can imagine the stress of handling and using 400 paper-based report while patrolling. Too often equipment was overlooked for inspection and over-maintenance of same equipment occurred. The effect of these inefficient activities was improper stocktaking and planning which led to higher cost of production.

Arriving at the Solution

Yokogawa Germany in cooperation with the R&D Department at Yokogawa headquarters, commenced a proof-of-concept (PoC) of the Field Assistant with UBE Spain. Following the successful completion of this PoC, UBE Spain provided the maintenance knowledge and data. Yokogawa analyzed this information and provided know-how on process control and industrial software applications.

The Solution and Benefits

The Yokogawa team developed a Field Assistant to allow the field operator to download digitalized check lists and documents. The task list prevents omissions in equipment inspections.

  • While performing maintenance, operator can refer to past maintenance logs and setting values.

  • Using the tablet, the operator can take photos, record audio, and video of any abnormalities. 

  • The photos, audio, and video of abnormalities can also be useful in training new operators.

  • A custom-made dashboard is available for the supervisor to view pending tasks, finished tasks, and ongoing tasks.

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  • Through the Field Assistant, data analytics is possible. Condition-based preventive maintenance is feasible which prevents unplanned plant shutdowns, by decreasing the likelihood of device failures, and giving more lead time for the ordering of replacement parts.

Digital Transformation is not limited to only the concept phase. It can go down to the shop floor level in the form of a Field Assistant.

Ammonium nitrate explosion at Beirut's port, and several similar accidents at different sites in manufacturing plants could have avoided, if proper field visits, faster information sharing, and timely action would have taken by the working staff.