Challenges

• Needed to centralize information for 15 workers

• Needed improved material status and location visibility for 252 shutdown/ turnaround (SD/TA) materials, located both on- and off-site

• Needed ability to tie together multiple plant operating disciplines within a short timeframe and accomplish overall goals as a single unit

• Mismanaged critical shutdown materials could potentially cost owner $100,000 per hour

• Material in laydown yard with passive RFID tag

• Needed a streamlined shipping and receiving process

• Needed to train workers to use Loop Material Readiness for simple implementation across all locations

Project specifics

• Execution timeframe of 3 months

• 252 SD/TA materials to be tracked on- and off-site

  • 144 valves

  • 87 pieces of equipment

  • 21 spools

• 15 Loop Material Readiness users

The Goal? Efficiency & visibility

Solution

The Material Readiness® solution was a monumental cost savings considering that temporarily lost materials or startup delays could have led to potential costs of $100,000 per hour. The hardware included 300 passive RFID tags and 2 TSL barcode scanners. The owner supplied two mobile tablets and four Android™ smartphones.

The project leveraged digital and real-time analytics to allow for precision workface planning and a live, centralized database for material and asset status and location. This kept project scheduling from chasing down materials during critical moments. This proved to be crucial, considering that the materials were transitioning through 15 different geographic locations.

Octave was able to help the client improve its shipping and receiving process with advanced notice of materials arriving on-site (What? How many? Priority?) and automated confirmation of shipped materials with the use of a gate reader at the facility entrance.

The value of Loop Material Readiness lies in the true visibility from planning to logistics to off-site calibration to material handling and staging to installation. Octave is able to help the client connect priorities with actionable decisions while executing the work.

Future SD/TA utilization

The project enjoyed great success. Additionally, the custom-er was able to visualize additional opportunities to drive value to maintenance and operations by using Loop Material Readiness.

Flange management:

This could provide actionable data for wrench time analysis, schedule updates, line and equipment updates, etc.

Pre-work scaffold data:

• Erection/release dates

• Regular inspection requirements

• Modification dates, turnover and maintenance

Permit tracking:

A permit barcoding system helps to determine who pulled the permit, when and where it was pulled and how long it was out.

On-Site Fuel management:

This will help determine which units were filled, where they were filled, how often they were filled and how much fuel was used.

Integration with Oracle’s Primavera P6:

This integration will automatically feed prioritized information to the centralized system of truth.

Attach equipment reports and data to specific materials for easy turnover:

• Vendor documentation

• Shipping bills

• Mud books

• MTRs