How a Leading Oil & Gas Service Provider Streamlined Inspections with Plutomen Workflow
Our customer is a renowned oil & gas service provider, which offer energy efficient oil, propane and gas furnaces and boilers across different parts of India. They offer a variety of furnaces and boilers that run on oil, propane, and gas, catering to different energy needs of their buyers. In addition to this, they also provide cleaning, repairing, and replacement services for oil and gas systems to ensure optimal functioning and extend their lifespan. With their emphasis on quality and energy efficiency, our customer has become a trusted name in the oil & gas industry in India.
THE CHALLENGE
The Challenge
Our customer was experiencing significant issues in their inspection processes due to several factors:
- Untrained Workforce: The company had onboarded several new inspectors who lacked comprehensive training on the detailed inspection procedures required for gas furnace systems.
- Inconsistent Inspections: There was a notable inconsistency in the inspection reports due to varying levels of expertise among inspectors. This inconsistency often led to missed steps in the inspection process, resulting in potential safety hazards and inefficiencies.
- Scheduling Difficulties: Scheduling real-time inspections was challenging, particularly during peak seasons, leading to delays and rushed inspections.
- Complexity of Inspections: Gas furnace inspections are intricate, involving multiple sub-components like filters, burners, gas lines, carbon monoxide detectors, furnaces, thermostats, system vents, and blowers. Improper inspection of these parts may lead to higher operating costs, potential risks, and inefficiencies in the system.
THE SOLUTION
The Solution: Plutomen Workflow to the Rescue
To address these challenges, our client leveraged Plutomen Workflow, a Digital Work Instructions solution, to create a step-by-step “Gas Furnace Inspection Checklist & Instructions” for their inspectors. The implementation included:
- Comprehensive Checklists: Detailed checklists were created to cover all critical components of gas furnace systems, ensuring that every aspect from air filters to thermostats was inspected thoroughly.
- Step-by-Step Instructions: Visual and text-based instructions were provided for each step of the inspection process. This included guidance on cleaning, checking, and replacing minor parts.
- Training and Onboarding: The digital work instructions served as a training tool for new hires, ensuring they had the necessary instructions and a checklist available to carry out inspections efficiently.
- Real-Time Scheduling and Reporting: Plutomen Workflow enabled better scheduling of inspections, ensuring timely checks and maintenance, especially during the high-demand cold seasons. The solution also facilitated real-time reporting and feedback, improving overall inspection quality and consistency.
- RealWear Assisted Reality Glasses Supported: Their inspectors were also able to access these checklists, and instructions directly by using RealWear assisted reality glasses. This greatly helped them inspect and troubleshoot any issue, hands-free.
Hence, the checklist and instructions were designed to ensure that each component of the gas furnace system was checked and verified, and all minor parts were cleaned, replaced, or repaired as necessary.
THE RESULTS
The Result
After utilizing the “Gas Furnace Inspection Checklist”, the gas inspectors were able to complete inspections in a timely manner, ensuring the long life of our furnace systems and efficient operations. The use of Plutomen Workflow’s digital checklists and instructions ensured that the inspectors did not miss any critical components during the inspection process, reducing the potential for system inefficiencies and higher costs. New hires were able to perform inspections effectively, reducing the training time and associated costs. Moreover, scheduling inspections in real time reduced delays and ensured that all systems were inspected and maintained properly, especially during the cold seasons.
As a result, the company not only enhanced the reliability and efficiency of its gas furnace inspections but also achieved substantial operational improvements and cost savings.
- 65% Increase in Inspection Rates
- 45% Increase in Productivity
- 90% reduction in Human Error
- 65% reduction in Training Cost
- 35% Decrease in Energy Consumption (a step towards sustainability)
We wanted our inspection process to be digitized with ready-made checklists and instructions. Plutomen Workflow was the solution we never knew we needed. It greatly helped us streamlining our maintenance operations throughout our service areas.
Manager
a Top Oil and Gas Producer
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