Joel recalls one event where he was monitoring and assessing alerts inside the AMS Device Manager application, where he discovered that a mass meter on a continuous process was showing a drive overrange alert that was increasing over time. Utilizing the embedded diagnostics and edge analytics within the meter, AMS Device Manager indicated a likely coating or plugging condition within the sensor tubes. The board operator didn’t notice any problem from the control room console, but Joel asked for a back flushing sequence, just in case. This cleared up mass meter plugging, and allowed Joel to later review the results with the area’s technical specialist and confirm that a latent problem had been averted. This early success was quickly promoted to Monsanto’s management team via an ‘AMS One-Page Success Sharing’.
This example was noteworthy because it not only proved the power of predictive monitoring as a means to avoid major downtime events— one that could have cost $1M in lost production, let alone repair costs—but it also began to reshape the minds of those around the Maintenance and Production Unit departments that Operations should embrace, care, and take Reliability seriously.