What are some of the challenges and rewards of working in plant operations?

Safety, efficiency and ergonomy can be improved at the same time. This happens when you involve the operation people and get the guidance of lean principles to improve the production process. Internal targets, motivation coming with management attention, recognition of good examples and rewarding are the key elements of continuous improvement.

To add to my virtual co-author's comments, it's important not to let safety regulations take precedence over actual safety. I've been at plants where the safety paperwork was so complex that little actual work was getting done. Then work is rushed and accidents more rather than less likely.

Although working in shifts seems to be a normal 8 hrs / day job from outside but it's not a piece of cake. Especially, night shift posses a challenge of keeping work life balance as well as mental and physical health. Plant operators should be rewarded for such shifts. When it comes to safety, again the decision making is with working shift. Usually, the decision making requires very less time and thus, there is this high stress movement in plant operator lives, which only operation guys will understand. Lastly, they are called area owners and of course they are! When operations team is up, your entire complex does well throughout the year.

Our plant has an outstanding safety record. The key is not letting managements push for job completion get in the way of working safely.

For Engineers and Chemists process safety can be the most challenging and rewarding area. Understanding what can go wrong and what needs to be put in place - barriers and mitigation - to prevent it happening and reduce the consequences if it does happen. Getting process safety right saves lives and saves companies from catastrophic events from which they might never recover from.

There are huge opportunities for improving plant operations through simple diagnostic measures and then changing the way you operate. Getting an additional 5-10% from a process can transform its profitability and give everyone involved a huge boost in confidence. If you’ve not read the book The Goal by Eli Goldratt would highly recommend it.

The knowledge coming from trainings and experience is the key for success in operations. The knowledge on the product, function of vehicle systems, software, process restrictions and limits, back up solutions and of course the skill and capacity based allocation of man power. Without the skilled operators, quality sensors, maintenance teams reaching the output and quality desired is not possible. Invest on Human and keep them engaged.

In plant operations, leadership is paramount. As a shift incharge, I emphasize the necessity of robust technical skills, crucial in emergencies. Quick decision-making is vital during troubleshooting, and in such moments, leading from the front is essential. Maintaining composure prevents panic among team members, ensuring discipline. It's inherent that subordinates respect a leader who doesn't leave them alone in emergencies, emphasizing the importance of consistent support and guidance.

Another benefit of working in operations is that you're getting realtime plant information and you're the first witness of it. You can experiment with certain parameters and get all the information on its effects on other parameters. You can make correlations better than anyone because you can judge the outcomes quickly.

Every team has its own responsibilities and targets to achieve but overall effectiveness and efficiency should be at the top of the agenda. Rational, data and knowledge based decisions should be made and the precise and accurate knowledge exchange is vital. Comments or ideas shared in a similar content to knowledge or facts can mislead the discussion and awful decisions. Whenever possible get together where the incident/case occures with the qualified people. Gemba de mimasho.

Shift work profoundly impacts professional growth, teaching valuable lessons in team management and humility. As a shift incharge, spending substantial time with the team throughout the year, even during gazetted holidays and adverse weather, fosters team building. Recognizing each team member's strengths and weaknesses is essential for capacity building. This knowledge enhances overall team performance, creating a cohesive and resilient unit. Shift work establishes a strong foundation for a collaborative and successful professional journey. Moreover, the shared experiences of facing challenges together during unconventional hours foster a sense of camaraderie among team members, ultimately leading to a more cohesive and resilient work unit

Based on my experience, the challenges in fostering teamwork and communication in a diverse workforce include overcoming cultural differences, addressing language barriers, and promoting inclusivity. However, the rewards include a rich pool of perspectives leading to creative problem-solving, increased innovation, and a more inclusive and dynamic work environment. Successful navigation of these challenges can enhance team cohesion and overall productivity.

Recognition serves as fuel for operational personnel, fostering a robust team dynamic. Appreciating small achievements, such as a junior team member's successful pump changeover or valuable contribution to emergency handling, is vital. Senior team members should acknowledge and praise these efforts, as it not only motivates the individual but also strengthens team cohesion. Operating in shifts, the operations team acts as the first line of defense during plant emergencies, being ever-present and the initial responders. Rewarding their dedication and proficiency is key to building a vigilant and resilient team. #OperationalExcellence

Working as an operations engineer is an ongoing learning journey, offering new insights daily. It goes beyond being just a chemical or mechanical engineer; it involves understanding all core engineering disciplines. In emergencies, quick and accurate decisions are pivotal. An operations engineer must diagnose issues related to instrumentation, electrical, mechanical, or process, requiring a comprehensive grasp of diverse disciplines. This holistic approach ensures effective and safe emergency handling, emphasizing the critical role of continuous learning in the dynamic field of operations engineering.

If challenging entropy is your idea of having fun then plant ops might be the place for you. All systems are naturaly bent on falling appart in an irreversible manner. The more complex the worse, and production plants are by no means an exception. So I think that the greatest reward comes from setting up procedures and processes that are inherently stable as much as possible and able to deliver constantly, even in the face of the nastiest surprise. Projects are great, change is great, but nothing beats day-to-day dependability.