Overview
The pandemic has forced companies to rethink how best to conduct business. A dizzying array of social distancing recommendations spewed forth from various government authorities, as the world watched the infection spread across the globe. Companies scrambled to respond. Globally, companies had to deal with differing recommendations and differing site dynamics.
ARC noted that companies that had begun the adoption of digitizing technologies responded easier to the challenges. Suppliers stepped up to support their customers with waved licensing fees and agile product enhancements to respond to pleas for help. Interestingly, none of the technology needed had to be created from scratch. After the “two-weeks to flatten the curve” phase, industry settled in for the long haul. In many ways, the environment in production facilities began to look similar to what it looked like at 3am on a Sunday morning.
What Is Your Plant Like at 3AM on Sunday?
It is 3 o’clock Sunday morning. Like most plants, it is staffed with only the minimal number of personnel to maintain production; just enough. Operators monitor the consoles with a shift supervisor nearby. There’s a handful of field operators making rounds and collecting samples. At the gates, one may find a security guard. The plant is producing at optimal capacity.
The administrative offices are empty; no human resource, accounting, purchasing, etc. In the event something should go wrong, a couple of engineers and some technicians are on call. Generally, though, they get to enjoy their weekend. They know it is their turn and next week it will rotate to others. Companies realize these skillsets are not needed on weekends, except under abnormal conditions.
But on Weekdays?
During the week, the scene at the plant is a different story all together. This was definitely the case pre-pandemic, but even during the COVID-19 the number of people in the plant increased during the week. You have engineers evaluating data, talking to operators (maybe) and technicians, and planning projects. Technicians pull work orders for routine maintenance and items that were not important enough to warrant a callout over the weekend.
But that is not all that goes on. There are production meetings, planning meetings, troubleshooting meetings, hazard analysis meetings, safety meetings, training, purchasing meetings, and “meetings at the watercooler.” It is interesting to reflect on all the different activities that happen during a regular weekday.
Do Plants Run Better Off Hours?
Interestingly, some companies have found that the plant runs better (e.g., more efficiently, better quality) off hours. One customer anecdotally told ARC that it realized about a 20 percent difference because of implementing restrictions related to the COVID-19 pandemic. Subsequently, this particular company has decided to make many of the changes permanent. By employing remote operations techniques, it has removed the need for many onsite positions. In its new mindset, many of these positions have become superfluous to the site or are more likened to “insurance.” Other positions, like HR or Purchasing can be consolidated at a central location or more centralized locations per country or region.
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Keywords: Automation, Remote Operations, Maintenance, Digital Transformation, Digitalization, Analytics, Artificial Intelligence, Machine Learning, Personnel Safety, COVID-19, Autonomous, Augmented Reality, ARC Advisory Group.
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April 25, 2021 at 01:55PM
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How the Pandemic Is Changing the Way Plants Run - ARC Advisory Group
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