Using DynAMo to Analize Alarm Patterns: Remediate Nuisance Alarms, Standing Alarms and Misconfigure...

Remediate Nuisance Alarms, Standing Alarms,

and Misconfigured Alarms

Using DynAMo® to Analyze Alarm PatternsTom Crowl P.E.

Jun 21, 2016

Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.

Genentech

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• Biotech Drug Manufacture

• Batch Process

• Oncology products

• FDA regulated

• Alarms and alarm response


CCP2-Cell Culture Plant 2

• Brought online in 2014

• Debug and Engineering Runs 2014-2015

• Qualification Lots started 2015

• New product 2016

• Periodic Alarm Review Quarterly Report

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What is DynAMo® ?

• Commercial Off-the-Shelf (COTS) software from a Honeywell –

Matrikon collaboration

• Alarm Query Tool used to gain information about all the alarms

generated from Experion CMs and Systems within CCP2.

• Generates alarm metrics, graphs, charts, and other figures useful in

alarm reporting

• Includes operator actions

• Provides historical information about alarms that is otherwise not

accessible and not viewable in the Alarm tab within the Station HMI.

• Has data from all servers

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DynAMo® Query Tools

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DynAMo® Query Tools

• Each of these tools provides

something slightly different

• Some organize information to

be used in reports

• Others have useful or

potentially useful information

for troubleshooting

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Harvesting data

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Narrow the Scope

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Filters can be applied to

make the report more

consise


In the Form That You Want

Simple easy to use interface

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Choose which columns are useful

for the report being producedOnce all options

from all 3 tabs have

been selected, click

Generate Report.


No More Custom Reports!

Export to Excel

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Reporting Tools

and Performance

Metrics

Alarm Identification

and

Troubleshooting


Quarterly Alarm Reports

Real Results

• 16732 alarm instances in first report

• 6452 in third report

• Down to 3209 in most recent report

• 81% reduction

• 35/day

• 1.5/hr

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Shift Reports

Awareness

• Started informal informational troubleshooting tool

• Morphed into daily email

• Expanded to wider audience

• Engrained into culture

• Notify the operations management

- All new alarms in the last 24 hours

- Standing alarms

- Unacknowledged alarms

- Operator actions

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Critical Aspects Mapping

All alarms are associated with critical aspect or safety

• Mapped all of the critical aspects of our process to alarms

• Made certain that every alarm has

- Appropriate Priority

- Appropriate Limits

- Enabled and disabled at the appropriate times during the batch

execution.

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Improve Alarm Focus

Enable the Personnel on the Plant Floor

• Default alarm view per area

• Training on filtering

• Standard Operating Procedures

- Timely Acknowledgment

• Training on DynAMo®

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Results

When an alarm occurs people react!

• >80% reduction in nuisance alarms

• Focus on critical attributes

• Shift reports

• Increased alarm awareness on the manufacturing floor

• Reduced alarm response times

• Alarm return to normal

• Operator acknowledgement

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Acknowledgements

Thank You!

• Tanner Garrett

• Jennifer LoPolito

• Sam Lin

• Peter Murphy

• Phil Cirino

• Siva Sundararajen

• Sean Schantz

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Using DynAMo to Analize Alarm Patterns: Remediate Nuisance Alarms, Standing Alarms and Misconfigure...

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