Operator Workload and Equipment Complexity
Stephen Maddox
I help engineers improve situation awareness in the control room so operators perform at the highest level when all hell breaks loose.
Measuring the complexity of equipment and its impact on workload is essential for optimizing operations, improving safety, and reducing costs. The plant design complexity may be intricate with the number of components, subsystems, and interconnections. Complex designs may require more monitoring and operational knowledge.
Operators are the keepers of the equipment and must know how the equipment is managed during normal operations and abnormal operations. We staff for normal and manage abnormal. Equipment with multiple operating modes, varying temperatures and pressures, or integration with various systems may create a higher operational burden. This is a major factor when assessing operator workload. Time and motion studies do not capture this. That is why we assign a score to every peice of equipment. A normal pump may have a low complexity score and a distilation column will have a high complexity score. Both add some complexity to the operator workload and must be included in the measurment.
Equipment must meet specific industry regulations that can add layers of administrative workload in terms of inspections, documentation, and reporting. Frequent breakdowns or maintenance needs can substantially increase the workload on staff. Complex equipment often requires more frequent and specialized maintenance which has an impact on operator workload. If complex equipment results in slower cycle times or produces more waste (off-spec products), it can indicate increased workload or inefficiencies.
Some equipment just has to be baby sat, that can have a huge impact on operator response. If an operator is focused on a section of equipment and does not know that a new problem is escalating in another area (tunnel vision) the result may be very costly. By measuring operator workload you can identify issues with lost situational awareness and high workloads that require resolution. Many stafifng study projects turn into HMI and alarm management projects. Could be the developement of overview displays, nuisance alarm reduction, or advanced automation solutions. It may require an organizational change. Complex systems may require more personnel or specialized roles to ensure adequate oversight and management. Complexity can influence shifts and overtime needs, particularly if issues arise on a regular basis which can lead to burnout.
Measuring the complexity of the equipment requires a little more effort than a time in motion study but it is very important. There are tools available: https://mycontrolroom.com/services/staffing-studies/
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When reducing workload is the goal, Process Optimization may be a key area for improvement. Re-engineering: Sometimes, the complexity can be addressed through process re-engineering or equipment upgrades, which can simplify operations and minimize workloads. Standardization: Where possible, standardizing equipment types and processes can reduce training requirements, streamline maintenance, and lower the overall complexity and workload.
Understanding the complexity of equipment and its implications on workload is crucial for improving efficiency and performance. By measuring various aspects such as downtime, maintenance frequency, and operational needs, industrial operators can identify areas for optimization, effectively manage their workforce, and ultimately enhance overall productivity.