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How can you use continuous improvement methodologies to enhance electrical safety and reliability?

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Electrical safety and reliability are essential for any plant engineering project, as they affect the performance, efficiency, and sustainability of the systems and equipment. However, achieving and maintaining high standards of electrical safety and reliability can be challenging, especially in complex and dynamic environments. That's why you need to apply continuous improvement methodologies, such as Plan-Do-Check-Act (PDCA), Lean, Six Sigma, and Total Quality Management (TQM), to constantly monitor, evaluate, and improve your electrical systems and processes. In this article, you will learn how to use these methodologies to enhance electrical safety and reliability in your plant engineering projects.

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Shadi Abdelkareem aleryani

+25Million Impressions | +44kFollower |Professional Electrical Engineering at OMV
Ramzi Aljilany

Senior Instrument and Control Technician at OMV | +35K Followers | +16M Impressions
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HN Armaments Directorate

1 PDCA Cycle

The PDCA cycle is a simple and effective method for implementing continuous improvement in any process or system. It consists of four steps: Plan, Do, Check, and Act. In the Plan step, you define the problem, identify the root causes, and set the goals and actions for improvement. In the Do step, you implement the actions and collect data on the results. In the Check step, you analyze the data and compare it with the goals and expectations. In the Act step, you standardize the successful actions, correct the failures, and plan for the next cycle. By applying the PDCA cycle to your electrical systems and processes, you can ensure that you are constantly identifying and solving issues, preventing accidents and failures, and optimizing performance and efficiency.

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Shadi Abdelkareem aleryani

+25Million Impressions | +44kFollower |Professional Electrical Engineering at OMV
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I'd like to share real-world scenario with the reliability of power supplies. The 86 caravans that make up the residential camp are supplied by diesel power plants. 448KW total calculated load. The load was supplied by 4 gensets (2X630KVA and 2X800KVA) using manual changeover switches. There were a lot of downtimes & highly operating costs (mostly for diesel). Lowering downtime and operating costs were the targeted goals. After collecting data, research, discussions, and brainstorming, it was decided to use adjacent flared gas through dual fuel systems and link the 4gensets to a sync. panel. The project was executed successfully. The outcomes were extraordinarily prosperous. Downtime dropped to roughly 2% annually & the opex was cut in half

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Ramzi Aljilany

Senior Instrument and Control Technician at OMV | +35K Followers | +16M Impressions
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The PDCA cycle, also known as the Deming Cycle or Deming Wheel, is a four-step management method used for continuous improvement in processes and systems. The four steps are: 1. Plan: Identify and analyze the problem or opportunity for improvement. Set objectives and develop a plan to address the issue. 2. Do: Implement the plan on a small scale. This could involve testing a new process, procedure, or system. 3. Check: Measure and monitor the results of the implemented plan. Compare the actual results to the expected results and analyze any differences. 4. Act: If the results are satisfactory, standardize the new process or system. If not, identify the root cause of the problem, adjust the plan, and repeat the cycle.

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2 Lean Principles

Lean is a philosophy and a set of principles that aim to eliminate waste and maximize value in any process or system. Waste can be anything that does not add value to the customer or the product, such as defects, overproduction, waiting, inventory, motion, transportation, and overprocessing. Value can be anything that meets or exceeds the customer's needs and expectations, such as quality, functionality, reliability, and safety. By applying lean principles to your electrical systems and processes, you can reduce costs, improve quality, increase productivity, and enhance customer satisfaction. Some of the lean principles that you can use are: value stream mapping, which helps you identify and eliminate waste in your electrical processes; 5S, which helps you organize and maintain your electrical workspaces; and Kaizen, which helps you involve your team in continuous improvement activities.

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Shadi Abdelkareem aleryani

+25Million Impressions | +44kFollower |Professional Electrical Engineering at OMV
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In this regard, I would like to give more details about the 5S approach. The 5S approach is a way to organize necessary objects so they are simple to find, use, and maintain. It all comes down to having exactly what you need—neither more nor less—to do your task when it's due. In brief: -5S is a set of procedures and guidelines for creating and maintaining a clean, tidy, and productive workplace. -Anyone can easily distinguish between normal and abnormal circumstances thanks to 5S. -Continuous improvement, zero defects, cost reduction & a safe work environment are all based on the 5S basis. -5S is a methodical approach to enhancing the work environment, our procedures & our output by including production line employees

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3 Six Sigma Methodology

Six Sigma is a methodology and a set of tools that aim to reduce variation and improve quality in any process or system. Variation can be anything that causes deviation from the desired outcome or specification, such as noise, errors, defects, or failures. Quality can be anything that meets or exceeds the customer's requirements and expectations, such as accuracy, consistency, reliability, and safety. By applying Six Sigma methodology to your electrical systems and processes, you can increase customer satisfaction, reduce defects and errors, improve efficiency and effectiveness, and enhance profitability. Some of the Six Sigma tools that you can use are: DMAIC, which is a five-phase process for improving existing electrical systems and processes; DMADV, which is a five-phase process for designing new electrical systems and processes; and FMEA, which is a tool for identifying and prioritizing potential failures and risks in your electrical systems and processes.

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4 TQM Approach

TQM is an approach and a set of practices that aim to achieve excellence in any process or system. Excellence can be anything that exceeds the customer's and the stakeholder's needs and expectations, such as innovation, sustainability, reliability, and safety. By applying TQM approach to your electrical systems and processes, you can foster a culture of continuous improvement, customer focus, teamwork, and leadership in your organization. Some of the TQM practices that you can use are: benchmarking, which helps you compare your electrical systems and processes with the best practices in the industry; quality circles, which help you involve your employees in problem-solving and improvement activities; and quality audits, which help you monitor and evaluate your electrical systems and processes against the standards and criteria.

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HN Armaments Directorate
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1.?????? Employee Training and Involvement: Provide extensive training to personnel. Encourage employee involvement in identifying safety issues and suggesting improvements. ? 2.?????? Continuous Monitoring and Measurement: Implement continuous monitoring systems. Regularly measure and analyze data related to electrical reliability and safety. 3.?????? Process Standardization: Standardize procedures for electrical maintenance and inspections. 4.?????? Error Prevention: Emphasize error prevention strategies through a continuous Improvement Culture.??Regularly review incidents and safety protocols. 5.?????? Data-Driven Decision-Making: Use data analytics to identify patterns, predict potential failures, and make decisions.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Ramzi Aljilany

Senior Instrument and Control Technician at OMV | +35K Followers | +16M Impressions
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In addition to above I would like to add Continuous improvement methodologies can be effectively utilized to enhance electrical safety and reliability in several ways: 1. Implementing methodologies such as Six Sigma or the 5 Whys can help identify the root causes of electrical safety incidents or reliability issues. 2. Developing standardized work procedures for electrical maintenance, operation, and safety protocols can ensure consistency and reduce the likelihood of errors or accidents. 3. Regularly updating and improving training materials and methods, organizations can ensure that employees are well-equipped to handle electrical systems safely and reliably. 4. Utilize KPIs to measure electrical safety and reliability.

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How can you use continuous improvement methodologies to enhance electrical safety and reliability?

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1 PDCA Cycle

2 Lean Principles

3 Six Sigma Methodology

4 TQM Approach

5 Here’s what else to consider

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