From Paper to Pixels: Transforming Operations with Shiftconnector®

How a Fertilizer Company Successfully Digitized Key Control Room Functions and Operator Rounds to Enhance Operational Efficiency

Highlights:

  • Successfully transitioned from paper-based system to all-in-one platform
  • Digitized log sheets, meter readings, handovers and operator rounds
  • Improved productivity and user satisfaction

Customer

A leading fertilizer manufacturing company in the Midwest USA.

Challenge

The client faced significant operational challenges due to its heavy reliance on a traditional paper-based, manual data collection system for log sheets, handovers, and meter readings.

The process was time-consuming, prone to errors, and made it difficult to analyze historical data and trends.

With numerous operator rounds across various departments like Ammonia, PSL (Storage & Loading), and Utilities, the company struggled with accessing and sharing data, assigning tasks, obtaining required approvals, and ensuring accountability.

The need for a digital transformation was pressing to ensure better organization and data management and to enhance overall productivity.

Solution

Recognizing these challenges, the fertilizer company partnered with Adatafy™, a Novaspect trademark, to implement the core Shiftconnector Plant Process Management System and Shiftconnector GO Mobile Rounds App.

Adatafy’s Software Engineering professionals initiated a project to design, configure and implement a comprehensive digital solution tailored to address the customer’s specific goals and functional requirements.

By taking a collaborative approach and gathering input from multiple users including operators, supervisors and superintendents, Adatafy developed a system that would improve each stakeholder’s day-to-day activities, be well-received, and obtain the maximum benefit for the organization.

The Shiftconnector deployment included the creation of 10 core application forms and functional requirements, covering critical areas such as:

  • Safety
  • Shift Attendance
  • Shift Handover (Operator & Supervisor)
  • Shift Report
  • Morning Meeting Information
  • Lock Out Tag Out (LOTO)
  • Temporary Bypass
  • MOC (Management of Change) Signoff
  • Major & IOW (Integrity Operating Windows) Alarms
  • Incident Requests
  • Production Rate Changes (automatically synced from dataPARC)

Also, with the addition of Shiftconnector GO, operators would be enabled to conduct rounds digitally (online or offline) using mobile data capture instead of relying on paper.

As the project progressed, the customer reviewed, tested and provided feedback in a development environment. Once approved, Adatafy conducted training sessions for administrators and key users to manage and utilize the system effectively upon launch.

Outcome

The Shiftconnector implementation marked a significant shift from a paper-based environment to an easy-to-use, all-in-one digital platform, resulting in improved data accessibility and operational efficiency.

The client reports their users are highly satisfied by the convenience of having a one-stop shop with more detailed information and a vastly improved handover experience.

Additionally, the successful initial deployment of Shiftconnector will lay the groundwork for future advancements. The company will be able to better leverage their data across other platforms to make informed decisions and maintain a competitive advantage.

 

Download the Case Study

 

FAQ

How can you digitize/automate operator rounds?

Digital operator rounds improves data accuracy, enhances operational efficiency, facilitates better data analysis, and reduces the time and effort required for manual data entry. It also helps in maintaining compliance and improving overall productivity. Automating operator rounds involves several key steps and the use of specialized software.

  1. Identify the specific needs of your operations, including the types of data to be collected, the frequency of rounds, and the roles of different personnel.
  2. Choose a software platform designed for operator rounds, such as Shiftconnector.
  3. Ensure the digital solution can integrate with your existing systems, such as asset management or maintenance software, to streamline data flow and reporting.
  4. Create digital checklists and forms that mirror your existing paper-based processes.
  5. Set up the software to match your operational requirements. This includes configuring routes, tasks, and data entry forms.
  6. Customize the system to include necessary fields, such as meter readings, safety checks, and equipment status.
  7. Start with a pilot phase to test the system in a controlled environment. Gather feedback from users and make necessary adjustments.
  8. Address any issues related to usability, data accuracy, or system performance.
  9. Roll out the system across all relevant departments and ensure continuous support and training.
  10. Monitor the system’s performance and user adoption, making further adjustments as needed.
  11. Use the data collected to analyze trends, identify areas for improvement, and optimize operations.

Featured Services

More Case Studies