Time-in-State® Management System
Limited insight into operational risk exposure within industrial production processes poses a threat to organizations’ financial performance. This is a particularly serious issue within the continuous process environment where most performance measurements lag behind the real-time process. The Time-in-State® solution provides an opportunity to manage these risks pro-actively and to deliver substantial financial gains.
What is Time-in-State®?
→ Time-in-State® is a process management system that implements operational excellence.
→ Time‑in‑State® implementations are guided by a MESA International endorsed methodology and supporting technology.
→ It has a long, successful track record utilising ‘big data’ and Industrial Internet of Things (IIoT) principles.
→ Time-in-State® establishes a unified/common performance measurement tool for production, process, quality, and asset management.
→ It secures the client’s human capital, facilitates change management and people development.
Time-in-State® in Practice
Time-in-State® is used to derive internal benchmarks by utilising process measurements, KPI and financial data. This assessment provides an accurate quantification of the operation’s
- economic performance when operating within and outside benchmarks; and
- operational risk exposure where operational risk is defined as the potential loss incurred as a result of system or process failure, or incorrect decision-making.
Time‑in‑State® translates operating and asset conditions into a measurement that correlates with the Return on Assets financial metric. This information provides an accurate assessment of asset and resource efficiency and effectiveness. Time-in-State® ensures a competitive advantage by extracting this information at (i) system1 level (can trace back problem to root cause) and (ii) in real‑time (resulting in pro-active management).
Overview of Time-in-State® application areas
Determine and quantify the state of the client’s operation prior to commencing with the project implementation.
Assess operational risk exposure to:
1. Determine the operation’s ability to operate within the Optimum Operating Envelope (OOE).
2. Quantify the proportion of time that the operation is operating within OOE.
3. Assess the project risk/probability of success in advance
Time-in-State® compares a production facility’s actual capability and capacity against strategic objectives.
Information presented by this assessment delivers insight into:
1. The operation’s economic performance under different market conditions (or seasonal constraints) e.g. high and low oil price conditions.
2. Appropriate operating target that maximise economic performance.
3. Time-in-State® is deployed to:
(a) Monitor and report how well strategy is deployed at operational level.
(b) Provide real-time guidance to operational personnel regarding the target state to standardised decision making.
Model-based Root Cause Analysis (Investigative Analytics for processing plants)
Substantial losses are incurred when operational personnel fail to identify the root cause of poor performance and do so in a timely manner.
Time-in-State® provides a platform to monitor systems (sub-processes) individually but in the context of the complete production process. This solution delivers:
1. Early warning of deteriorating performance at system level.
2. Common action to adverse conditions (standardization).
3. Immediate feedback regarding the effectiveness of corrective actions.
Pro-active Management of KPIs
The performance reporting for most continuous production processes is limited retrospective performance measurement. These measurements include lagging laboratory analysis, overall equipment effectiveness (OEE), production costs, equipment availability, etc. In most cases this results in poor employee engagement as operational personnel are not able to proactively manage these performance metrics (and these performance measures are often directly tied to the annual bonus scheme).
A Time-in-State® solution delivers:
1. An accurate definition of the inter-relationship between process/equipment operating states and (retrospectively) reported performance measurements.
2. Participation of all personnel in deriving the optimum operating envelope at system level which in turn facilitates:
- Common understanding of standards to be maintained within the process and functional units.
- Alignment between technical and process disciplines.
- Logical breakdown of the production process into system.
- Pro-active management of performance.
- Change management.
3. Employee development – the Time-in-State® methodology facilitates training and development of people.
4. Asset management – sustaining various systems in their respective optimum operating envelopes result in lower equipment stress and consequently extend equipment life and lower maintenance cost.
5. Condition based equipment maintenance – Time-in-State® delivers early warning of deteriorating equipment performance by comparing process measurements with pre-defined baselines.
Energy is a huge cost contributor in asset intensive processing plants. Energy efficiency is a function of how well the respective systems are managed.
Time-in-State® provides functionality to:
1. Quantify the energy variance under different operating conditions. This provides insight into:
- The percentage time that the operation is achieving optimal energy efficiency.
- The key influencing factors contributing toward variance.
2. Define baselines, at systems level, that deliver best energy efficiency practices.
3. Utilise baselines to pro-actively manage the process to attain high energy efficiency.
Securing Human Capital
People interpret data based on their experience, understanding, and biases developed during their training and operation of the plant. Incorrect decision‑making results in substantial financial losses and increases risk exposure.
Time‑in‑State® offers a solution that:
1. Captures best practices by integrating knowledge and understanding of all operational personnel (a library of knowledge is established).
2. Facilitate operational decision making by:
- interpreting process and equipment conditions consistently; and
- providing contextualised text-based feedback in real-time to operational personnel.
1 System: In the context of Time-in-State®, a system consists of multiple elements fulfilling a specific purpose or function within the production process. A system is defined in the context of a process function or equipment functional unit. An element is described by a measurement of calculated value. The inter-relationship between the elements characterises behaviour and operating state of the system. Overall performance is a function of multiple systems – the desired or target performance will be realised by default if all systems operate within the optimum state. Time-in-State® places the focus on managing systems in their optimum state – achieving the latter will result in peak performance.