DIGITIZING INSPECTION ROUNDS IN MININGIIOT At Work

TABLE OF CONTENTS

 3   Industrial Companies: The Case for Digitizing your Operator Rounds

 4  The 4th Industrial Revolution     3 defining characteristics      Technology requirements      Benefits of digitizing field work

 5   The Challenges of Legacy Operator Round Processes     Oil & Gas / Petrochemicals     Aerospace     Mining     Top 6 Challenges

 7   Strategic Motivations for Digitizing Operator Rounds

IIOT at Work. The Case for Digitizing your Operator Rounds | Industrial Companies: The Case for Digitizing your Operator Rounds 3

The fourth industrial revolution has taken hold. Call it the industrial internet of things (IIoT). Call it Industry 4.0. For industrial companies that rely on paper- based operator rounds, this new layer of technology means transitioning to a smarter, more connected, and more profitable way of doing business.

Predictions of a paperless office have been greatly exaggerated. As universal as business computers and mobile devices have become, we still love paper. From the tangible appeal of a favorite trade magazine to the longstanding custom of capturing information with paper, pen, and a clipboard, the legacy of paper lives on. But such examples are far from equal, especially in business.

Companies that rely on manual, paper-based data collection now find themselves falling behind their digitally enhanced competitors. And industrial companies that rely on paper-based operator rounds are not immune.

In the 1990s, internet technology gave businesses a faster, easier, and less expensive way to communicate and share information: email. Today, industrial companies – especially in aerospace, oil and gas/petrochemicals, and mining – have discovered how using internet and mobile technologies to transform their paper-based operator rounds into end-to-end digital workflows yields even greater benefits.

1INDUSTRIAL COMPANIES: THE CASE FOR DIGITIZING YOUR OPERATOR ROUNDS

This is IIoT at work – made possible by the digitization of data in real-time and centralized access to that data in the Cloud.

–  Greater data transparency – receive and respond to inspection data in real-time

– More operational efficiency

–  Greater productivity and safety for workers

– Enhanced compliance

–  Reduced costs and greater profitability

–  Better worker satisfaction and retention

– Easy to deploy and scale

IIOT at Work. The Case for Digitizing your Operator Rounds | The 4th Industrial Revolution 4

3 DEFINING CHARACTERISTICS1.  Rapid technological change: Technology adoption cycles are becoming shorter

and shorter – and products are becoming obsolete faster.

2.  Connectivity: To adapt, companies must become increasingly connected and automated throughout their operations, and across devices and technologies.

3. Growing complexity: This process is incredibly complex due to the vast range of connected technologies and devices that must communicate.

TECHNOLOGY REQUIREMENTSDigitalization

–  Transitioning from paper/manual inputs to a completely digital, data-driven enterprise from the ground up.

–  Can be used to enhance plant operations and drive greater performance and business agility.

Virtual, augmented, and mixed reality

–  Brings relevant and personalized data and guidance to the worker.

–  Integrates digitized information with technology to present key, real-time data to the worker via connected smart glasses, smartphones, or tablets.

BENEFITS OF DIGITIZING FIELD WORKCompanies that embrace the fourth industrial revolution and connect their field operations with a mobile solution will find an immediate payoff:

Several industrial incidents emphasize the importance of effective logging and shift handover. On July 6, 1988, a large fire and explosion on the Piper Alpha offshore platform killed 165 and destroyed the facility. A relief valve on the platform was removed for service and a blank had been loosely installed in its place.

THE 4TH INDUSTRIAL REVOLUTION 2

Fast ROIBy using the smartphones and tablets that workers are already familiar with, companies gain rapid ROI thanks to operational efficiencies and cost savings. In turn, these results can then support further automation and connectivity initiatives.

Simplified execution and tracking of complex processesDynamic work instructions lead workers step-by-step through changeovers and complex procedural variations. This enables production teams to fluidly handle greater demand for customized products and orders.

An eager, receptive workforceDigital platforms help you recruit and train younger workers eager to use new technology; ease ongoing retraining of all workers to handle increasingly complex processes; and enable you to provide multimedia training, remote coaching, expert consultation, and inspections.

Next, we’ll contrast these benefits by considering the most common challenges facing industrial companies using legacy operator round processes.

IIOT at Work. The Case for Digitizing your Operator Rounds | The Challenges of Legacy Operator Round Processes 5

3THE CHALLENGES OF LEGACY OPERATOR ROUND PROCESSES

OIL & GAS / PETROCHEMICALSWhether inspecting machinery in the plant or conducting field inspections and testing, this illustration shows the kinds of workflow challenges and inefficiencies common to operator rounds that rely on manual, paper-based processes.

For stakeholders in any industrial company, it’s not difficult to see how the challenges and inefficiencies illustrated below translate to their own operator rounds.

The fourth industrial revolution has taken hold. Call it the industrial internet of things (IIoT). Call it Industry 4.0. For industrial companies that rely on paper- based operator rounds, this new layer of technology means transitioning to a smarter, more connected, and more profitable way of doing business.

AEROSPACEQuality control inspector. Civil aviation safety inspector. Flight operations inspector. Whatever the job title may be, safety is every aerospace inspector’s mission. It begins with an aircraft’s construction and pre-delivery inspection. It continues with every unannounced ramp check and pre-flight inspection. At every level, inspectors must stay up-to-date on safety regulations and technology. The lives of passengers and crew, and the livelihoods of the people who work in the industry, are at stake.

It’s demanding work. For example, consider a day in the life of a flight operations inspector for a commercial airline. From the exterior-walkaround to the flight deck and cabin inspections, they work in a high-pressure, deadline-driven environment.

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The existing FieldOperator TaskManagement is notdigital, achievingseamless integration automatically is difficult.

Existing workflowsmake it difficult to run extended processanalytics to derivevaluable insights.

Contextual information related toassets / equipment’s / device type,health, maintenance history etc is noteasily accessible.

Adherence to SOP on the field is a challenge. Activity tracking andscheduling is manual leading tomultiple missed checks and multiple human errors.

Field operator task execution is mostly manual. Creation, allocation,execution and data/event collection ismostly on paper.

Overall System visibility is lacking.Difficult to locate Operators on the field& validate who is doing what? & why?

There are no collaboration tools noraccess to digital artefacts such astraining videos and documentation

DAY IN THE LIFE OF A FIELD WORKER

IIOT at Work. The Case for Digitizing your Operator Rounds | The Challenges of Legacy Operator Round Processes 6

There could be a leak in the hydraulic system – or worse, a crack in the fuselage. Whether it leads to a quick repair or a cancelled flight and rescheduled passengers, an inspector’s ability to accurately document findings and immediately communicate problems is essential to safeguarding the flying public and the airline.

MININGMine operators perform multiple inspections in their crusher and screening plants. Surface mine operation inspectors focus on equipment and surface effects. They must determine compliance with health and safety laws and regulations, and address any violations. For example:

–  Is there enough room for excavation equipment in the active mining areas of the pit?

–  Is secure machine guarding in place to protect workers?

–  Is the highwall’s angle of repose being maintained?

– Are chemicals properly contained and labeled?

Health and safety are equally important underground. A day in the life of a ground control engineer for an underground mine might begin in the engineering office. After a discussion about ground support specifications, the engineer travels down the drift. There are a variety of inspection points throughout the mine to ensure that safety measures and policies are being followed. For example:

– Has proper sanitation and ventilation been established?

–  Do ground conditions at the rock face present any potential geological hazards?

–  Are mine workers properly trained to check scale and load explosives?

– Are they wearing the required personal protective equipment?

–  Above ground and below, identifying and correcting hazardous conditions are essential to protecting the health and safety of workers and the general public.

TOP 6 CHALLENGES

Manual data gatheringMost activity tracking/scheduling is manual and paper-based, leading

Limited end-to-end visibilityNo visibility during inspection process. Field technician whereabouts and status are unknown.

Downtime and inefficienciesRoutes, workflows, and processes are not optimized for peak performance, leading to downtime, inefficiencies, and time wasted between tasks.

Incidents and issues without resolution/safetyInadequate visibility into operator rounds makes it difficult to diagnose safety incidents. Best practices cannot be accurately set.

Training and transitionTraining documents are old and outdated. Antiquated tools make it difficult to train an aging workforce.

Inadequate complianceMany processes are old and not compliant with new regulatory and safety norms set by state and other agencies.

IIOT at Work. The Case for Digitizing your Operator Rounds | Strategic Motivations for Digitizing Operator Rounds 7

4STRATEGIC MOTIVATIONS FOR DIGITIZING OPERATOR ROUNDS

There are 4 strategic factors motivating industrial company executives to modernize their end-to-end inspection workflows:

Industrial company operator rounds are at a crossroads: Transition to a digital solution, or stay the course with legacy processes and risk damaging the company’s long-term viability.

As part of a connected workforce solution using the Honeywell Cloud, Honeywell Forge Workforce Productivity - Inspection Rounds brings greater efficiency and effectiveness to any business’s operator rounds.

WE CAN GET YOU THEREHoneywell has been helping industrial companies optimize their businesses for over 100 years. During that time, we’ve completely transformed the way we do business – and so have our industrial customers. We can help you do the same.

Honeywell Forge Inspection Rounds

Our easy-to-use software solution digitizes end-to-end inspection workflows. As part of a connected workforce solution using the Honeywell Cloud, Honeywell Forge Inspection Rounds brings greater efficiency and effectiveness to any business’s operator rounds.

Digitize data. Connect workflows. Be productive.

Honeywell Forge Inspection Rounds enables you to digitize both simple and complex workflows. Orchestrate all of your in-plant and in-field operations with one, interconnected software solution.

–  Optimize worker and process performance

–  Drive continual improvement

–  Increase safety and competency

–  Build a smarter, more connected, and more profitable business

Data digitizationAll data is collected and stored digitally – no manual paperwork or filing. Dashboards and analysis are at your fingertips.

End-to-end workflow visibilityComplete visibility into the process – so you know which worker conducted which activity at any given point. Reconstruct scenarios to understand the whole picture and make better decisions.

True business agilityUnderstand in real-time what’s driving quality, set benchmarks, and increase uptime. All while on the go.

World-class user experienceMeet and set new standards with advanced technology that will ultimately increase profitability and drive better business results.

IIOT at Work. The Case for Digitizing your Operator Rounds | Strategic Motivations for Digitizing Operator Rounds 8

No lost data – runs on the device and in the Cloud

Working in remote locations, including underground mines, means you can’t rely on an operator rounds application that requires wireless internet connectivity. That’s another advantage of Honeywell Forge Inspection Rounds. It runs directly on your mobile devices – with or without an internet connection – so any data captured is data saved.

With wireless internet connectivity, Honeywell Forge Inspection Rounds gives you real-time transmission of inspection data through the Cloud. No Wi-Fi available or lost the connection? No problem. Honeywell Forge Inspection Rounds works offline and will automatically synchronize your data in the Cloud when connectivity is available.

Device-agnostic, so you can maximize your existing IT investments

Honeywell Forge Inspection Rounds gives you the flexibility to use your existing hardware assets. It works on any smart mobile device, computer, or smart wearable, on any operating system (Android™, Apple® iOS, macOS®, Linux®, Windows®).

That won’t change.

Use the computers and smart mobile devices that make the most sense for your business and your mobile workers. At any time, you can scale your operations with the latest rugged mobile devices from Honeywell or another brand.

Honeywell Forge Inspection Rounds runs directly on your mobile devices – with or without an internet connection – so any data captured is data saved.

HONEYWELL FORGE INSPECTION ROUNDS: TOP 10 VALUE DRIVERS FOR INDUSTRIAL COMPANIES

VALUE DRIVERS COO PLANT / GROUND / MINE MANAGER SUPERVISORFIELD / AIRPORT / MINE OPERATOR

Digitization •

Cost Savings •

Compliance • •

Optimization •

Operational Risk •

Root-Cause Analysis •

End-to-End Visibility •

Productivity • • •

Safety • • • •

User Satisfaction • •

For More InformationLearn more about how Honeywell Forge

Inspection Rounds can help in effective

shift handovers, visit our website

www.InspectionRounds.com or contact your Honeywell account manager.

Honeywell Connected Enterprise

715 Peachtree Street NE

Atlanta, Georgia 30308

InspectionRounds@Honeywell.com

EUR +44 (0) 162 562 62 50

USA +1 208 921 9867

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