Resin manufacturer Resinkem, a 50% joint venture between AECI and US-based Georgia-Pacific Resins, has implemented ApplyIT’s operations information management system, FlexiLOG, to manage shift handovers, tighten reporting, track history and ensure accurate data for efficient decision making.
Part of ApplyIT’s operations performance OpSUITE, FlexiLOG is designed to provide a user friendly electronic method to log and process shift information simply and accurately. Prior to the FlexiLOG implementation, Resinkem relied on a manual system to manage its shifts using hand written reports logged in A4 hardcover books. This process was not only time consuming but unreliable with readings for critical processes such as tank levels often not recorded accurately. Resinkem operations manager, Manoj Ram, says the old logging process was cumbersome and erratic. The logbook was not always accessible between shifts and, being manual, it had no back-up in the event of loss or damage, the risk of data loss was high.
Building on the existing platforms
The operations team at Resinkem were already enjoying the efficiencies of ApplyIT’s OptiRUN for managing and planning plant maintenance activities, and SmartSURE for capturing, reviewing and reporting SHEQ-related activities. “FlexiLOG was an obvious choice, both from a system quality perspective and for ease of use,” says Ram.
The system went live two weeks after implementation: “Good communication between the ApplyIT team and Resinkem ensured the transition to the new system went smoothly and we were able to go live quickly with very few changes,” explains Ram. “FlexiLOG now manages information on all plant operations at Resinkem, including shift handover logs, batch sheets and downtime records. Having critical data readily available allows the plant supervisor management to utilise resources more effectively and management make timeous decisions.”
Templates add structure
“The template-based format of FlexiLOG requires the input of information in a structured manner, promoting the communication of critical information that directly affects production. The templates compel the foreman to provide information of specific details about the shift, this requires precision in reporting, ensures accuracy and provides traceability,” says Ram.
The quick trending facility in FlexiLOG tracks data from the previous 10 inputs and monitors process patterns based on comparisons of performance and output. The information provided by the system forms a basis for generating reports, managing key performance criteria and diagnosing and resolving faults.
The operations team has also used FlexiLOG to create an instruction log into which the production manager inputs requirements for the foreman in a structured format pertinent to specific plant areas. ApplyIT product director Scott Bredin says FlexiLOG has complemented Resinkem’s use of OptiRUN and SmartSURE through their operating and reporting processes. “We have configured a section in FlexiLOG that summarises all work orders (through OptiRUN) and outstanding incidents (through SmartSURE) per shift. This creates an awareness of maintenance requirements and incidents during and between shifts, so the foreman can make decisions based on current information.”
Bredin summarises the benefits FlexiLOG offers: “The name says it all – it is a flexible operator log book solution. What makes FlexiLOG unique is that it also supports workflow processes and so provides an audit trail.”
Future plans for using FlexiLOG at Resinkem involve empowering each of the plant’s operators to write their own shift log, with the foreman inputting a summary of the day’s shifts.
For more information contact Scott Bredin, ApplyIT, +27 (0)31 514 7300, [email protected], www.applyit.com
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