Momentive:

How PermitCliq & LotoCliq made their PtW process safer, faster and more economical

Results on safety

• PermitCliq and LotoCliq serve as a basis for enhancing safety and efficiency and provide Momentive with an additional tool for ensuring safety. 
• The new system proved much clearer and more logical, and is therefore more user friendly.
• A significant improvement in the prevention of accidents and near accidents has been realized.

Results on efficiency

• A simple push of a button provides the necessary information on the material and people needed and how much time certain activities will take.
• It is easier for planners, operators, shift supervisors and maintenance crewmembers to coordinate their activities.
• During stops there are practically no waiting times on material and
• better planning and preparation enable Momentive to reduce the time spent on specific activities by 16 – 25%.

Background
Momentive Specialty Chemicals B.V. is located in Pernis and has about 300 employees. It is one of the largest of Momentive’s plants. Momentive is an American company with locations in the USA, Asia and Europe. At the Pernis plant it produces raw materials for the production of epoxy resins and semi-finished epoxy resins for a variety of companies, for example in the construction and automobile manufacturing industries. Momentive aspires to achieve ‘Excellent HSE Performance’. According to Momentive, HSE is more than just the concern of the HSE department alone; HSE is embedded in the core values of all departments in the entire company.

Challenge/ambition
In the summer of 2009, Momentive decided to add a Lockout/Tagout system to the iBanx PermitCliq permit-to-work system. This system would replace the MSR system, which is no longer supported by Shell, the former parent company. The maintenance department installs connecting flanges and other isolations; the production department is responsible for indicating where they need to be installed. In preparation for this work, Momentive identified all locations/points where isolations needed to be made. They were drawn, given a unique number and set in templates. The production and maintenance departments work together more effectively by making use of isolation lists and multi-coloured labels. The production department labels a location where maintenance must install an isolation; maintenance performs the task and returns the labels (and the sign-off sheet) to production; production can then use the list and labels to check the isolations. This list and labels of different colours are used in a similar way to monitor and manage isolation removal and pressure tests. iBanx suggested working together with Momentive to further develop the LotoCliq system by incorporating best practices and by integrating Momentive’s specific needs. An interview with Martin Bakker, Health and Safety Specialist and Dirk Dullaart, Shift Team Leader, about training, implementation and their experiences with LotoCliq, the new system.

The improvement project
A team consisting of people from both iBanx and Momentive got to work. An application was developed in close consultation with all team members. The application replaces the elaborate functionality of the old MSR system and it provides even more opportunities for improving isolations. For example, new functionality was introduced that makes it easier for planners, operators, shift supervisors and maintenance crewmembers to coordinate their activities. Furthermore, it is now also possible to add activities to the isolation lists in addition to the Loto locations (where connecting flanges are inserted, for example).

"Our current operations are safe, of course, but this system provides us with an additional tool for ensuring safety." 

Results
The first major production stop with LotoCliq was a bit more troublesome than expected. Because of circumstances the conditions were tested little, therefore it was an exciting step into the unknown. Dullaart: “Particularly young users, who could already work with the new system, solved most of the problems. The new process meant a change in behavior where mainly older operators faced difficulties. Meanwhile, everyone on site is trained and accustomed to working with the systems.” After the initial hurdles had been taken, the new system proved much clearer and logical, therefore more user friendly. Besides, the system also serves as a basis for enhancing safety and efficiency. Now, more than one year later, LotoCliq is also used for appropriate time estimation and makes plans for stops more specific.

"During stops we have people who walk around two or three days. Planning wise it’s possible to cut back on half a day with this tool because of better preparation."

Bakker: “In advance there is an estimation made of the number of flanges that are being opened during a stop. Each flange takes a certain time, say 15 minutes. On that basis, an estimation is made which leads to a more specific schedule. This makes that the preparation and final sprint, cost less time. During stops we have people who walk around two or three days. Planning wise it’s possible to cut back on half a day with this tool because of better preparation.

After the first stop in 2010 Dullaart already indicated: "Our current operations are safe, of course, but this system provides us with an additional tool for ensuring safety. The extensive information on the labels are used as an extra check. All this extra information is very important for ensuring safety, since we work with exotic gaskets in all shapes and sizes." Using LotoCliq made the preparatory procedures for production stops considerably easier. The system will mean greater efficiency but also savings in time on the preparations.

"With LotoCliq you know with just a push of a button how many and which gaskets you need, how many people and how much time it will take."

Bakker: “It is also a tool for planning, a ‘shopping list’ so to speak for preparing a production stop. Imagine we have a seven-storey factory and we need to burn off on the seventh level. In the past, we had to go up, count, come back down, we would realize that we'd forgot something, so back up we would go and we would then have to write out lists manually. With LotoCliq you know with just a push of a button how many and which gaskets you need, how many people and how much time it will take. Ideal for planning!" In the past for example we lost hours on wrong orders. During stops there appeared to be a surplus or shortage on gaskets. The latter is a bit harder of course. Since it caused us to loose time. During the last stop, which took three and a half weeks, we have had virtually no waiting times on material on which LotoCliq is used. The process runs a lot better which saves time and money."

"During the last stop which took three and a half weeks we have had virtually no waiting times on material on which LotoCliq is used. The process runs a lot better which saves time and money."

Progress
In the past year LotoCliq and PermitCliq were connected so that a work permit can only be issued once the isolations are in place. Before activities to the equipment take place it is procedurally guaranteed that these get rinsed and cleaned. To avoid exposing workers to dangerous substances, after rinsing the equipment is separated of the process by placing flanges. To carry out the activities there is a work permit drafted in which all measurements and agreements of the activities are registered. Because of the connection between both processes it’s not possible to hand out a work permit before all flanges are registered electronically. Bakker: ”Overall it took a while before the employees were used to it. In former times it was easier to circumvent the process, just updating the list by hand and proceed. Now, the system provides a blockade. The result is a significant increase in security that leads to a decrease in accidents or near accidents.

"The result is a significant increase in security that leads to a decrease in accidents or near accidents."

User experiences
Jakob Senneker, Chief Operator: “The ‘shopping list’ works great for placing orders. We want to be as economical as possible. Even in the planning phase we want to know the exact types and quantities of gaskets we will need. These days our orders are very accurate compared to the past. We don’t over-order, and that saves us money. These gaskets cost three or four hundred Euros a piece, which is pretty pricey. Ten gaskets represent a considerable capital expense."

Guus Cramer, Senior Operator: “Being a web-based system, LoToCliq has a number of clear advantages compared to the old system. I can get information in advance on things that need to get done, because I can log in from home and see what’s going on. That’s great at the end of a weekend or holiday. In the past you had to wait till you were on site to get this information. The new system really saves us a lot of time." 

Improving your PtW process