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About Ethydco / Operational Excellence

 

 

ETHYDCO approach to operational excellence:

Because we believe that excellence among all is best for all, ETHYDCO operational excellence (OE) approach is a systematic and collaborative approach that works on the integration between the total quality management systems, performing processes and human behaviors` to enable safe, reliable and efficient operations. It provides the tools to identify and turn opportunities into realized improvements.

The approach recognizes the operational and business challenges inherent in our global business. OE`s methodology is aimed at striking the optimal balance between the discipline gained from structured global processes and the quick decision making and personal ownership derived from an experienced-based organization.

To achieve Operational Excellence, we combine the best management systems, globally recognized technologies, Six Sigma methodology, Lean Manufacturing, and a proven culture-change model to provide integrated solutions.

OE establishes a common language and approach that drives consistency in performance across the whole organization, as we believe that "If the interaction between people, process and systems is right, the results will take care of themselves."

 

Control Excellence:

One of the fundamental elements of operational excellence which enable ETHYDCO to Operate with industry-leading asset integrity and reliability, is to pursue control excellence, control excellence is an industrial automation began with the measurement and control of all manufacturing processes and also enabling unsurpassed levels of operational efficiency. Operational efficiency essentially equates to maximizing the throughput of the operation while simultaneously minimizing energy and material consumption.

ETHYDCO Complex encompasses a variety of process technologies where Automation systems used to manage these process work to operate in a safe environment and optimize production quantities and qualities. These disparate systems strive to reach a common goal by serving managers, engineers and operators but are extremely complex as each subsystem is best-in-class focusing on a narrow aspect of the business. Integrating them into an enterprise-wide solution proved to be an ideal platform for the integration, orchestration, and reporting/ visualization framework for this overall solution.

With such a powerful platform the barrier between the business side and the engineering and production side of the plant is completely removed. ERP which is used to manage business data (such as production orders, schedule, and material costs), can now receive quality production data from the Operations Management layer through one seamless interface. Such high quality, reconciled production information and other operating parameters can also be used for performance management.

 

PIMS (Plant Information Management System)

(PIMS) is a family of applications and tools that gather manipulate and make operational information readily available to the engineering and management staff in the proper context for each user and presented in an instantly understandable visual form.

The PIMS shall collect all process data from the DCS and store it in the historian database.

The PIMS shall assist the ETHYDCO in executing its continued improvement process through the provision of long term historical and real time data and a respective set of tools.

The PIMS shall provide an interface to a spread sheet program for further data processing by ETHYDCO engineering / management staff.

The PIMS shall be based on client server architecture. The server shall be a rack mounted server computer.

The PIMS will offer the following functionalities:

  • Collection and long term storage of process data, alarm and event data from DCS.
  • Advanced data analysis including filtering and averaging of data.
  • Data import and export.
  • Web interface.
  • Backup and recovery of data and system backups.
  • Interface to process control systems and business network via firewalls.

Data from subsystems will be transferred to DCS via defined interfaces for storage of process data, alarm and event data where required.

Backups of secure data shall be suitable for safely, highly reliable and traceable storage over a long period.

 

LMS (Logistics Management System)

Logistic management system is robust platform covering all process stages along the process chain from the reactor through to shipping logistics. This will ensure product logistics flexibility and also the transparency and documentability of goods flows to the works for subsequent processes are fully satisfied.

LMS permit reliable identification of all product flows and consignments from production through to shipping, including all relevant data for production and quality, management and warehouse optimization through to order picking and shipping of individual customer orders. Due to a standardized and certified SAP interface it is also possible to integrate direct communication with a higher-level ERP system. Plant operators therefore have online access to all current inventory data for production and sales purposes.

 

LIMS (Laboratory Information Management System)

ETHYDCO laboratories utilize Laboratory Information Management System, LIMS which is an essential tool in improving the data quality and operational efficiency of product quality control process.LIMS logs every action and every record, enforces signatures, archives for future retrieval, and provides data integrity and traceability.

LIMS enables monitoring and enforcement of staff training and certification, equipment inspection, calibration, and maintenance by denying data entry unless all equipment maintenance and training requirements are met.

LIMS means that the data can be easily tracked, sorted, and retrieved reducing paper use; reducing handling errors and improving response times.

LIMS considered an excellent means of meeting complex data archiving, retrieval, and auditing needs, and for complying international regulatory bodies.