EQUIPMENT HEALTH CARD

(TRACKING OF INTERLOCK STATUS OF A DEVICE)

Team Members
1. Neela Panikar
2. Dhaka Jitendra
3. Rohit Kumar Singh
4. Shambhavi Kumar
5. Sriram Dantu
 PROBLEM STATEMENT

After Bypassing or Modifying the interlock of an equipment is not recorded in any

digital platform

Chance of • Equipment failure

failures • Accidents
• Environmental Hazards
• Quality issues
 REFRAME THE PROBLEM

• The logic & interlock bypassing of a equipment should be Digitalized or not?

• How can a logic & interlock bypassing of a equipment can be Digitalized?
• What is the Current process following for that? How can we Digitalized?
• How many cases are highlighted Due to missing of normalizing the logic change over?

Symptoms Underlying Problem

 Due to lack of information to all Departments an equipment can be damaged

Chance of Equipment failure when it is operated while some interlocks are bypassed.
 No Communication between user & maintenance Departments

 As some safety interlocks are bypassed it can lead to accidents when it is

Accidents operated while some safety interlocks are bypassed.
 PROBLEM UNDERSTANDING
Process Flow of a Bypassing or logic Modifying for a equipment
Stakeholde

“X” person Department Operation Plant Head Instrument CCR

Head of “X” Head Dept
r

• Request • Approving • Approving • Final • Complete • “x’ will

for the the Approval the give
Bypassing permission permission requirement informatio
Activity

or logic to “X” to “Dept of “x” n only to

Modifying Head” CCR
for an
equipment

Bypassing or logic Modifying for a equipment

1. Instrument Department will complete the requirement of “X” –No pain to that department
2. “x” Person -No pain to “X” department
3. Other Departments in the plant doesn't Know that Some thing is Bypassed –Pain for these Department

Process
1. “X” person will raise the request for “Bypassing or logic Modifying for a equipment ” to do some
maintenance activity for some time.

2. After approval from Department Head of “X” , Operation & Plant Head. Request of “X” is completed By instrument
Department. Finally the information will be given to “CENTRAL CONTROL ROOM “ Only , Which is not correct.
Present Format
 STAR MODEL APPLICATION

System refinement for TRACKING OF INTERLOCK STATUS OF A DEVICE

1. System based Work flow for roles in

SAP
2. Power & Authority
• Plant Head –
• Operation Head
• Department Head
1. Create awareness of
Digitalization
2. Workshop for engineers on
Process awareness, Safe work
procedures

Decision on Bypassing & logic modification

1. Ageing report (Overdue days)
2. Safety performance
1. Track the Increase in ON TIME
NORMALIZING %
2. R&R for teams maintaining 100%
achievement in ON TIME
NORMALIZING %
 RECOMMENDATIONS/ SOLUTION

• Create a mechanism to track & Communicate the TRACKING OF INTERLOCK STATUS OF A

DEVICE .
• Report with Case Ageing of each INTERLOCK STATUS OF A DEVICE FROM the date of bypass.
• Assessment: Identify the reasons why should this TRACKING OF INTERLOCK to be digitalized
• Submission of Request should be Hard & soft copy(Through SAP).
• Processing through a channel.
• Internal Audit.
• Communication Hierarchy.
• An equipment should bypass with all safety measures
1. Prior information should be given to Process department to avoid “UNSAFE ACTS” &
“UNSAFE CONDITIONS”.
2. Priority for compliance – All SOP should be followed.

• Weekly information Should be given to all Departments to prioritize the Over Due Bypassing or logic
change for a equipment.

• Communication to “X” person for expected date of normalizing the modification done by him.
 PROCESS OF CHANGE
How would you build the urgency of this
problem to be solved?
1.Can avoid Breakdown related to equipment
2.Can Avoid accidents
3.Can reduce environmental Hazards
4.Enhance the equipment life
How would you Communicate the
urgency of this problem to be solved?
1.Depicting the dangerous impact of existing
practices on Human safety & Equipment heath
in long term
2.Presenting to management about positive
outcome to support the change in economical
terms.
Identify stakeholders that are important
for the solutions to be approved.
1.All Department Heads
2.Operations Head (User dept.)
3.Safety Head
4.Environmental Head
5.All employees & Workmen
Identify stakeholders that are essential
for solutions to be implemented
1.Operation Shift in charge
2.Maintenance shift in charge
3.Site safety officer
PROCESS OF CHANGE
How to sell the idea to get it approved
1.Highlighting the benefits of system in
contributing towards individual safety.
2.Positive outcome for reducing environmental
hazards.
3.Increasing productivity & thereby What kind of metrics would you use to
contributing in revenue generation.
monitor the change?
1.On time Normalizing Of Changes done in
What kind of competences would you Logics & interlocks %
need to be developed among employees 2.By tracking the Near miss NUMBERS
or change the implementation team? 3.Comparing the frequency of Breakdown
1.Better Analytical skills Before & after
2.Good Listener 4.Analyzing the data related to production
improvement
3.Proactive approach
5.Rewards & Recognition to best performer
4.Leadership commitment individuals/Plant
5.Rewards & Recognitions
6.Transparency
7.Professionalism
8.Team work
THANK YOU