Real-time Accountability

Inspection rounds are routine observational checks carried out by field operators throughout a chemical manufacturing facility. These rounds involve systematically examining equipment, processes, and environments to ensure everything functions accurately. The goal is to identify any potential issues before they escalate into significant problems, thereby maintaining the smooth operation of the facility and ensuring overall safety.

At the heart of inspection rounds is the process of meticulously documenting observations. Inspectors might use various tools to record data, take notes and capture photos. This documentation is critical because it creates a detailed record of the facility's condition at specific points in time. These records are invaluable for tracking trends, identifying recurring issues, and providing evidence of compliance with industry regulations.

Compliance with industry regulations and standards is another critical aspect of inspection rounds. Chemical manufacturing is heavily regulated, with strict guidelines governing everything from environmental impact to worker safety. Regular inspections ensure that the facility adheres to these regulations, reducing the risk of fines, legal issues and reputational damage. In the U.S., chemical manufacturers must comply with the U.S. Occupational Safety and Health Administration (OSHA) Process Safety Management (PSM) Standard (29 CFR 1910.119), which mandates rigorous safety protocols for processes involving hazardous chemicals, including regular inspections and maintenance of equipment. In the EU, the Seveso III Directive (2012/18/EU) requires chemical manufacturers to take key safety measures to prevent or mitigate accidents, including regular inspections and maintenance of equipment. Compliance with these and other national and international standards requires a systematic inspection process with clear documentation and record keeping.

In most chemical plants, inspections are still completed using manual checklists and pencil-and-paper notes. These notes may be later transferred to a shared Excel spreadsheet or similar system. Why the continued reliance on these archaic methods? Inspectors often must cover a lot of area as they move through the facility and grounds, perhaps even visiting multiple buildings on a larger campus. Wi-Fi may be spotty, which means field operators are not directly connected to the control room at all times during the inspection. That makes pencil-and-paper notes a convenient stopgap for inspectors on the go. However, this can lead to a number of problems, including:

• Lack of a systematic inspection process, leading to inconsistencies in observations and recommendations between inspectors and incomplete documentation.

• Data loss and errors, due to poor handwriting, lost paper notes, idiosyncratic notetaking methods, or input errors when transferring data from written notes to spreadsheets.

• Time delays in transferring important information from inspection rounds to shift supervisors or maintenance staff.

• Inefficiencies due to the manual process and the necessity of transcribing notes from paper to spreadsheets.

Here's what that can look like in practice: A field operator downloads the mobile app to a smartphone or tablet that she takes with her during inspection rounds. The app provides a checklist, tailored to her plant and areas of responsibility, which she can download for offline access. As she makes her rounds, she checks items off the task list and enters required observations or data into the app. She can also snap pictures to support her observations and store the photos right in the app. When she is back online, data is automatically uploaded to the PPM and sent to the control room. If there are follow up items to be completed, a task is automatically generated and assigned to the correct department for action. All relevant notes and photos are appended to the task for faster problem-solving and resolution.

With a mobile inspection round app, inspections are completed to a clear standard, and everyone has access to real-time information and results. Accountability tools ensure that follow-up tasks are routed to the right people and taken care of in a timely manner. That leads to better equipment performance and reliability, reduced downtime, lower operational costs, and improved safety and compliance.

eschbach created Shiftconnector^® GO to streamline inspection rounds and keep field operators connected to production, maintenance and management. It’s an easy-to-use mobile app that puts the power of Shiftconnector^® in your pocket, online or offline.