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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
Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
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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Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
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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Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
DynAMo® Query Tools
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Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
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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Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
Harvesting data
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Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
Narrow the Scope
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Filters can be applied to
make the report more
consise
Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
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.
Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
No More Custom Reports!
Export to Excel
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Reporting Tools
and Performance
Metrics
Alarm Identification
and
Troubleshooting
Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
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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Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
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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Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
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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Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
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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Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.
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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