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- Traced 14 upstream assets
- Pulled 6 historian trends
- Read the filler and capper interlocks
Root cause: pasteurizer PST-201
Its heat exchanger faulted at 1:29. The surge tank covered for 45 minutes, then the capper starved. The capper isn't broken.
- Pulled 32 active alarms from SCADA
- Grouped them by cause
- Ranked them by process impact
32 alarms, 3 events. One needs action now.
A cooling water pump tripped. Reactor R-3 has about 20 minutes before its high-high limit.
- TI-310Reactor R-3 temperature high
- P-204Pump trip
- FT-118Flow deviation
- PT-311Jacket pressure low
- FT-118Flow deviation
- L2-CHGChangeover in progress
- FT-118Flow deviation
- + 25 more
- 17 Cooling water pump P-204 trippedAct now: start standby pump P-205.
- 9 FT-118 chatteringNo process impact. Schedule recalibration.
- 6 Line 2 changeoverExpected. Suppress during changeovers.
- Traced rejects back to their stations
- Pulled 30 days of scrap and rework
- Sized each fix against the target
Three fixes, about +3.3 points of yield
Most of the loss is fill-level drift and out-of-spec capping, not line speed.
- Correct fill-level driftFIL-301 underfills after long runs.+1.5
- Recalibrate capper torqueCAP-401 torque drifts out of spec.+1.0
- Cut changeover scrapFirst 20 minutes after each changeover.+0.8
- Root cause in minutes
- First-line operator support
- Proactive fault detection
- Alarm management
- Yield optimization
Why did robot R3 stop?
R3 is waiting on the clamp interlock. Supply air PT-12 dropped to 3.9 bar, below what valve V-12 needs, after the regulator was replaced (WO-4471).
- and more