Case Study TOTAL Raffinerie Mitteldeutschland GmbH Finito Digital Shift Book

Transcription

1 + Case Study TOTAL Raffinerie Mitteldeutschland GmbH Finito Digital Shift Book 1/5

2 Project data: Customer: TOTAL Raffinerie Mitteldeutschland GmbH Country: Germany Branch: Refinery Employees: around 630 Task: The existing shift report application should be replaced by a new software solution. In addition, further applications and data should be integrated. Company: The TOTAL Raffinerie Mitteldeutschland GmbH at the chemical site Leuna is one of Europe s most modern refineries. The product range includes gas, diesel and fuel oil as well as liquid gas, raw gas, aviation fuel, bitumen and methanol. Among others, three million tons of gas are produced every year. That widely covers the requirements of Saxony-Anhalt, Saxony and Thuringia: Around 1,300 gas stations in the catchment area of the refinery get their supplies from Leuna. The distillation plant processes 30,000 tons of raw oil on average per day which mostly comes via pipelines into the storage tanks from Russia. The finished products are loaded and get to the market via street, rail and pipeline. Solution: Finito Digital Shift Book is used as standard software for administration of information, incidents, tasks and instructions. It was possible to implement additional customized requirements as the application is very adaptable.» I have an overview within a shortest period of time if there were any anomalies lately, changes in the production process or safety-related issues. I am able to react immediately. «Thomas Born Plant manager at TOTAL Raffinerie Mitteldeutschland GmbH» New Solutions is used to work with producing companies. The specialists are speaking the same language as we do and also know which risks are related to changes with systems like ours. «Reinhard Hofmann IT manager at TOTAL Raffinerie Mitteldeutschland GmbH Case Study Finito Digital Shift Book 2/5

3 Finito Digital Shift Book customizable standard software for use in refinery A report system for all instances The employees of TOTAL Raffinerie Mitteldeutschland GmbH use the electronic shift book software Finito Digital Shift Book to record incidents and information of the daily shift operation. The cross-plant report system is flexible, easy to handle and archives data audit-proof. Plant manager Thomas Born starts his day well informed. First of all, he checks the reports of the day, evening and night shifts online, which are exported out of the electronic shift book system of the TOTAL Raffinerie Mitteldeutschland GmbH. The 41-year old plant engineer, who is responsible for catalytic processes is also checking the refinery s overall shift report daily: I have an overview within a shortest period of time if there were any anomalies lately, changes in the production process or safety-related issues. I am able to react immediately. The reports are also centrally available for Borns staff, who work in the following shifts. Furthermore, there are entries which are relevant for their current shift as instructions to be taken care of, new safety or handling instructions and maintenance processes. Also the latest plant status as well as the quality parameter comparisons, the plant performance or energy consumption. You can t manage this information transfer with shift books made of paper, emphasizes Born. Developed in a refinery s environment A large amount of the 630 TOTAL Raffinerie s employees is working in shift operations. Different shift systems exist parallel, as usual in the producing business: the fully continuous shift system in the production process, the partly continuous shift system for shipment and the 24-hour shift for safety as well as daily and extra shifts. All shift systems are considered in the electronic shift book software of the refinery. TOTAL Raffinerie in Leuna is using Finito Digital Shift Book since This solution was developed by New Solutions GmbH in Burghausen in a refinery s environment and could be adapted to the plant s requirements quickly. The web-based solution which can be used via the standard browser was used ever since and was repeatedly customized due to the requirements of the departments and the management. Our key users are able to do small adjustments and inform or train their colleagues. So we don t have to assign our project partner for every small detail, says IT manager Reinhard Hofmann. One record is sufficient For data records the departments use so-called data headers as information, availability, filling supervision, energy, etc. Predefined fields, text modules and a possible electronic signature eases the input for employees. A main concern for the electronic shift book software Finito is that no employee has to record an information twice. For this reason, incidents are categorized and transferred depending on a trigger or via push of a button to a following shift for example. The departments define which way an information has to go or what a trigger is. The Finito access is protected via single-sign-on with the plant ID card. Therefore, the information is safe from unauthorized access. Furthermore, it can be tracked who recorded or changed which data. Individual functions like shift handovers at shift transfers can be assigned to the shift manager for example. All entries are saved audit-proof in a central data base after finishing the shift. Any changes after the shift transfer are recorded and in the shift report. In contrast to self-made shift book solutions Finito is recognized by offcial bodies. Overall refinery report tool TOTAL Raffinerie uses only Finito as overall refinery report tool with which also superordinate topics as plant performance, energy management or availability are monitored. Therefore, relevant values are defined so Finito can compare them with the actual values. They are getting to the OSIsoft PI-system via an interface. The better and more reliable a plant operates, the safer and more economically it is. Every shift staff who works in the report system of Finito can track our performance with defined priority parameters, explains plant manager Born. Case Study Finito Digital Shift Book 3/5

4 The same applies to the energy management systems of the refinery, which is certified according to ISO since The daily target/actual-comparison in Finito leads the shifts into dealing with energy and its optimization. Build and use know-how With Finito you can determine how many hours every shift worker was working on which plant. You can see if the employees have been at different plants regularly so they won t lose the appropriate know-how. Shift- and overall refinery reports are available at the push of a button as Finito saves all information and incidents from the shift operation. Finito functions as some kind of a knowledge data base. The employees can search for prior entries and recapitulate or reuse already found solutions. Evaluations about quality-related features can be used for quality management and serve as input for an ongoing improvement process. Assist and advise TOTAL Raffinerie is very content with their electronic shift book software. If there is a need for it the experts of New Solutions GmbH are available online or via phone for the refinery employees at any time. A corresponding maintenance contract provides defined Service Level Agreements. New Solutions is used to work with producing companies. The specialists are speaking the same language as we do and also know which risks are related to changes with systems like ours, says IT manager Hofmann. TOTAL Raffinerie already has several solutions from New Solutions and some parts were explicitly developed for the plant. We benefit from the good and open communication with our software partner and feel well-advised all the time, says plant manager Born.» We benefit from the good and open communication with our software partner and feel well-advised all the time «Thomas Born Plant manager at TOTAL Raffinerie Mitteldeutschland GmbH Case Study Finito Digital Shift Book 4/5

5 Technical overview: Finito Digital Shift Book Finito Digital Shift Book, a product of New Solutions GmbH, is a software solution based on the latest generation of Microsoft technologies. The modular structure of the application enables customer-specific extensions without affecting the update ability. Latest development methods in connection with quality assurance and test tools guarantee a high above average software quality. Contact: New Solutions GmbH Marktler Str Burghausen Tel info@new-solutions.com Photos: TOTAL Raffinerie Case Study Finito Digital Shift Book 5/5