In a large plant, you will encounter many assets of varying complexities, as well as different strategies for performing condition monitoring based on asset criticality. For some assets, you may not need any strategy or the strategy might be simply to run to failure. On the other extreme, there is a high-end, sensor-based system that continuously monitors your assets through an Industrial Internet of Things-based system. However, for all the assets that fall somewhere between these two categories, implementing rounds makes a lot of sense for most organizations.
Until about 2015, most organizations were still inclined to implement pen-and-paper-based rounds, but with most operations going digital, rounds are following the same path. In this context, rounds refer to the digital implementation of manual condition monitoring and operator data collection through a mobile platform, where operators use smart mobile devices to record their responses and sync the data to a server. This article addresses some of the many challenges involved in this implementation, grouped into two main categories: People and Technical.
People
Rounds significantly involve human interaction, not only during the deployment phase, but also in daily operations. This includes people from multiple disciplines, from the field operators, supervisors and teams responsible for designing and maintaining the routes to the strategy / reliability team that reviews the collected data and even the IT teams.
Here are some common challenges observed in many implementations:
- Operator Resistance – It's natural to expect some resistance when there is a major organizational change. This can come from tech savvy engineers who prefer old tools over new ones or skilled operators who are knowledgeable about daily plant operations, but less familiar with using a smartphone. Navigating menus and settings, and understanding the new rounds product workflow can be overwhelming for operators. Additionally, specific features of the rounds solution, such as near field communication (NFC) tags and barcode scanning, may require operators to be at an exact location to take readings, which could be rather inconvenient as this is a behavior change.
- Supervisor Dilemma – Plant supervisors might recognize implementing rounds as a necessity for increased productivity and long-term benefits. However, they must work closely with operators daily and handle numerous inquiries from field operators about the implementation. This consumes a great deal of the supervisors’ time, at least during the initial stage of rounds implementation. It means supervisors need to be well-versed with the workflows of the rounds solution and even know about some troubleshooting techniques in the product to help mitigate operator resistance.
In both cases, training is crucial, not only on how to use the rounds product, but also in engaging operators with the broader organizational goals of digitizing plant operations and understanding the potential benefits of rounds implementation.
Technical
One can hardly imagine a day without the Internet now, utilizing it for just about anything, from travel to shopping. But with regard to plants, these questions need consideration: Does your plant have Internet connectivity? Is it feasible to have Wi-Fi or cellular reception in your plant? Perhaps it’s a situation like a power distribution company, where transmission lines that need to be inspected are in the middle of a forest. Does your IT team know how to distribute mobile apps? Does your security team allow it? Are there any policy changes or approvals needed from your security team? These are some of the challenges that need to be discussed with all parties involved much earlier in the implementation.
Some of the considerations in this category are:
- Connectivity – The location of the plant, interference from equipment, and data security issues can all pose challenges to achieving a connected plant. If you are fortunate enough to have network reception across the plant, you have fewer concerns. If not, understanding how your rounds solution works—whether it requires continuous Internet connectivity or can operate offline—will help you plan better and lay the groundwork effectively.
- IT Challenges – In some cases, working with your IT department can be as challenging as working with a third-party vendor. Many organizations lack established policies or may have stringent policies regarding smartphones. These devices are often treated differently from laptops. For instance, traffic from smartphones or mobile devices may go through a different virtual private network (VPN) and authentication protocols, even though they are connected to the same network. In some cases, mobile devices are locked and are not allowed to download apps from a public store.
In both cases, planning is crucial. Understanding what is required for your rounds implementation and involving your IT team early in the process will help in setting up the necessary infrastructure or obtaining the required approvals on time for a successful implementation.
Conclusion
A successful implementation of rounds in a plant environment requires a comprehensive understanding of both human and technical challenges. From a human perspective, it is crucial to engage all stakeholders early in the process, ensuring clear communication and collaboration between departments, such as IT and security. Addressing people-related challenges involves fostering a culture of adaptability and continuous improvement, where employees are trained and motivated to embrace digital tools over traditional methods.
Technically, the complexities of achieving a connected plant highlight the need for a robust network infrastructure and thoughtful integration of mobile solutions, considering factors like connectivity and device management policies.
By proactively addressing these challenges, organizations can lay the groundwork for a more efficient and responsive operational framework, ultimately enhancing their asset management strategies and operational reliability.