Safer Work SchedulesAn Innovative Approach to Crew Scheduling

Kerry Hamlett, BP AmericaSteve Heise, ePM

Kerry Hamlett, BP AmericaSteve Heise, ePM

BP America Decatur, Alabama• Specialty chemicals for plastic

bottles and high-performance polyesters

• Over 1 million tons per year produced and shipped

• Six production units or “trains”

• 800 employees and contractors

• 24x7 operation

Docks• 250 barges per year at

irregular intervals

• Inbound feed stocks

• Outbound finished products

• Two-man on-duty crew for 24 to 48 hours

Outside Battery Limits (OSBL)• Twice-daily inspections for

leaks and other malfunctions

• Not performed when the on-duty crew are servicing barges on the dock

Other Crew Duties• Routine maintenance

• Contractor permitting

• Special projects such as renovations and repairs

• Training and certification

• Cover for training time and other absences

Crew Scheduling Challenges• Too much overtime can

interfere with employees’ personal lives

• Substitutions are limited by skill and certification requirements

• 24x7 operations are especially challenging

Organization Simulation ModelsSimVision® Better-Informed Decisions

• What-if scenarios

• Organize the work differently

• Change policies and practices

What-If Scenarios and VariationsOperations and Demand• Number and types of barges• Barge arrival timing• Number of trains operating• Production rates and

volumes• Mix of products• Pipeline availability• Rail car availability

Organization and Work• Separation of duties• Specialized sub-teams• Total manpower• Work schedules• Crew sizes• Overtime policy• Training methods

Simulation Scenario Examples • Average demand exceeds

capacity by about 3 operators

• More at peak times when several barges arrive in close succession

• Backlog represents unfulfilled OSBL inspections and maintenance

• To offset the shortfall requires– 3 additional full-time employees– 30% to 40% overtime– Some combination of the two

Operator Demand (FTEs)

Operator Backlog (FTE-days)

Capacity4 Crews of 2

Operators Each

With 30% Overtime

Simulation Scenario Examples• Varying combinations of

demand and organization

• Safety: communication and coordination

• Process: conformance to procedure

• Product: conformance to specification

Simulation Scenario Examples• Varying conditions and

policies• On-duty crew size• Annual barge traffic• Multiple back-to-back barge

arrivals• Organization of the work• Maintenance and

inspection schedules

Conclusions• Better-informed decisions

• Quantify trade-offs

• Explore many alternatives

• Balance many competing factors

• Applicable to any industry

• SimVision®