Production operators are valuable resources to plant reliability-based asset management strategy, as they are the closest person to the machine and are usually the first to detect even the smallest changes in process conditions and machinery health, such as abnormal readings, leaks, signs of corrosion, weird noise, excessive vibration and heat.
Unfortunately, most of the time their observations are not reported at all and no remedial action is taken quickly. Because of this, sometimes it will be too late to effect changes that could reduce equipment break down, prevent stop of production and safety incidents.
ODR is one of the best practices that empower operators to be part of the plant reliability strategy where people, processes and technology is integrated. This will bring positive change to the organization’s culture that encourages the operations, maintenance, and reliability departments to communicate and work together more effectively towards mutual reliability goals.
Safety observation program is always needed and has been implemented in most of the plant nowadays in order to help them to prevent injuries, by helping people to talk to each other about safety and increasing safety awareness among the staffs of the plant. With such program in place, the real costs of accidents can be measured and controlled.
In order to achieve this, safety observation card or log sheet was assigned to respective departments and personnel to record down their observation and feedback about the plant safety conditions. The data from the cards was later being entered into spreadsheets for monitoring, assessment and further analysis.
Unfortunately, due to the limited resources in safety department nowadays, sometimes these data will remain inside the cards or log sheets as it was too time consuming to be put into digital form. As a result, most of the time the up to date plant safety level can only be accessed once or twice a year. Worst still, it may not be accessed at all!
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