Manufacturing companies routinely and frequently invest millions of dollars in new facilities, process equipment, and renovations. Such investment are made with the hope that production capacity will reach all time highs.  When expectations aren't achieved, managers and supervisors become frustrated.  Unfortunately, the elements that aren't addressed adequately are those that impact the operators directly.  We're talking about operating procedures, job aids, system descriptions, and of course, effective training that ensures equipment will be operated as intended.  As an outside, independent entity, S&A, Inc. will provide a clear perspective on your existing operating practices.  S&A, Inc. will work to develop these types of documents in a user friendly format that will facilitate efficient plant operations.

Here are a few areas where this type of initiative will benefit your organization.

·        Operators will be more aware of asset maintenance interventions and administer these interventions in a timely mariner.

·        Operators will operate the process more effectively, efficiently, and safely

·        Product related quality issues will decrease and production efficiency of the process should increase.

·        The quality of the training process (including cross-training) will improve

SYSTEM DESCRIPTION

The System Description (SD) is developed to include a specific description of the process, from raw to final product, storage or shipping, etc. The SD includes technical details, design precepts, as well as operating conditions and parameters. Major subsystems are included, as are support systems and significant pieces of related equipment.

The SD typically includes a detailed discussion on the control schemes and interlocks (safety) that are used to control and manipulate each (sub)system and components.  Content will include how and when the control room and local control stations are used to direct operations or production.

The typical format includes a table of contents, purpose and scope statements, diagrams, terms and definition, and detailed content in logical sequential flow. The final format will be defined in consultation with your management staff.

OPERATING PROCEDURES

S&A, Inc. can develop the content of standard operating procedures, SOPs, for the (sub)systems and equipment listed under the SD work scope. This effort will ensure that practices are defined and are consistent with current plant conditions and operating practices.

Content will be reviewed, revised, and validated to be consistent with plant conditions and operating practices. S&A, Inc. will interview designated personnel, perform plant tours, and observe actual operating practices to establish (validate) procedure content.

Procedure format will be defined in consultation with your management staff. 

The basic procedure structure typically includes the following sections:

• Start-up
• Normal operations
• Shutdown
• Abnormal operations including emergency operations
• Attachments – (Job Aids, Checklists, Reference Materials)

JOB AID DEVELOPMENT

To facilitate effective and consistent job performance, S&A Inc. will develop appropriate job aids.  Examples include checklist, placards, schematics, overviews, laminated wallet references, and station postings to name a few of the more prevalent forms.  Properly designed, job aids will make for a safer work environment and more productive employee.