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Operating Discipline (OD)

Operating Discipline (OD). Presented to ES-317y at UWO in 1999 Dick Hawrelak. Operating Discipline Origin. Developed by Bob Boldt, Sarnia Division Manager, in the early 1980s. OD is about the history of plant know-how.

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Operating Discipline (OD)

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  1. Operating Discipline (OD) • Presented to ES-317y at UWO in 1999 • Dick Hawrelak

  2. Operating Discipline Origin • Developed by Bob Boldt, Sarnia Division Manager, in the early 1980s. • OD is about the history of plant know-how. • OD is about preserving and transfering know-how so we don’t have to learn the same lessons over and over again.

  3. Definition of OD • OD is the knowledge and understanding of thousands of details required to operate efficiently, reliably and safely and the dedicated attention needed to ensure their use all of the time.

  4. Other OD Features • OD is about management of systems including; procedures and good operating practices. • OD is concerned with training new plant superintendents as they tackle new assignments in production.

  5. OD Concerns • Critical process operating conditions (reactor temperatures, furnace combustion ratios). • Mundane operating details (lubrication schedules, maintenance procedures, keeping P&Ids up-to-date, managing pipe specifications).

  6. OD Council • The Div. Mgr. heads a OD Council of experts including, engineering, research, maintenance, instrumentation, marketing, etc. • When a new Plant. Superintendent is appointed, one of his first tasks is to up-date the OD Book for that plant. It takes about 3 months to up-date the OD Book.

  7. The OD Book • This is a summary of: the design book, process flowsheets with heat and material balances, P&Ids, the operating manual, the emergency manual, S&LP incident records, research activity, competition, marketing opportunities, etc.

  8. OD Presentation • Within 3 months of a new appointment, the new Supt. must make a presentation to the OD Council to demonstrate that he has learned the thousands of details required to operate the plant efficiently, reliably and safely. • The council questions the Supt to see if he has learned all the past mistakes and they either pass or fail his appointment.

  9. Results • OD proved to be a very effective way to transfer know-how. • OD was applied throughout Dow’s global network from about 1980 till 1995. • As a result of downsizing in the 90s, most of the council experts had retired and the concept that was concerned with history became history.

  10. Possible Exam Question. • Describe what is meant by Operating Discipline at Dow Chemical.

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