Six Sigma Alarm Management
“DCS alarm systems are designed and configured by thoughtful engineers who sincerely work to provide information to operators so they can do their jobs safely, efficiently, and with a minimum of needless harassment. Therefore most alarm systems are welcomed with open arms by plant operators.”
While the logic seems to follow correctly, many people that work in processing facilities would greet the statement above with a bit laughter. Alarm system configurations are often the source of confusion, irritation and occasionally can get in the way of getting to the root of a processing problem. When Monsanto planned to covert one of its PROVOX systems to a DeltaV digital automation system at the Soda Springs, Idaho phosphorous production facility they decided to reexamine their alarming system to generate significant improvements. They published their methodology (DMAIC), tool sets (fishbone diagrams, analyzers), and results in articles featured in Control magazine “Six Sigma Alarm Management Part 1 (766KB PDF) and Part 2 (217KB PDF).” They achieved reduction of integrity errors by 95% overall, audible alarms by 44% resulting in a 62% reduction in operator loading. If you’d like to improve operator performance in your facility, this article may have valuable tips on how to go about it.
