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Handling Observations

In this final section of the Blueprint Paper Mill tutorial, you'll learn how operators and supervisors handle observations—abnormal conditions identified during operator rounds that may require follow-up action.

What is an Observation?​

An observation is a recorded abnormal condition or noteworthy finding discovered during an operator round. Observations are created when:

  • A reading falls outside normal operating range
  • An operator selects "yes" for abnormal condition checkboxes (e.g., "Unusual noise or odor?")
  • An operator adds a photo with descriptive notes
  • Equipment behavior deviates from expected norms

Phase 1 captures observations for documentation and handover. Phase 2 (future) will add automated alerts, severity levels, and triage workflows.

Creating Observations During Rounds​

Automatic Observation Creation​

Observations are created automatically when readings are out of range. Let's revisit the Feed Pump P-404 example:

During the round, the operator recorded:

  • Bearing Vibration: 7.2 mm/s (normal range: <6.0 mm/s)

What happens:

  1. Field turns red 🔴
  2. Alert shown: "Above normal threshold (>6.0 mm/s)"
  3. Operator prompted to add notes
  4. Operator adds: "Audible knocking sound from drive end bearing. Pump still operating but needs attention."
  5. Operator captures photo of pump bearing
  6. Observation automatically created and linked to this route stop

Manual Observation Creation​

Operators can also manually create observations for conditions that don't involve abnormal readings:

Example: During the Cooling Tower CT-03 route stop, the operator notices visible algae growth in the tower basin. All readings are normal, but the condition needs attention.

The operator:

  1. Selects "Yes" for "Visible algae growth?" checkbox
  2. Adds notes: "Algae buildup on south side of basin. Recommend cleaning before buildup gets worse."
  3. Captures photo of algae
  4. Observation created: "Cooling Tower CT-03 - Algae Growth"

Observation Details​

Each observation includes:

Metadata​

  • Asset: Which equipment (e.g., Feed Pump P-404)
  • Route Stop: Which route stop identified the issue
  • Timestamp: When the observation was made
  • Operator: Who recorded it (e.g., John Smith)
  • Route: Which route the round was following (e.g., Morning Shift - Pulping & Utilities)

Content​

  • Title: Auto-generated or operator-provided (e.g., "Feed Pump P-404 - High Bearing Vibration")
  • Description: Operator notes explaining the condition
  • Readings: Associated readings that triggered the observation
  • Photos: Visual documentation
  • Severity: Manual classification (Low, Medium, High, Critical) in Phase 1; automated in Phase 2

Example Observation Record​

Observation #47
Created: 2025-06-15 at 6:23 AM

Asset: Feed Pump P-404
Location: Unit A – Pulping, Pump Room
Route Stop: Morning Shift - Pulping & Utilities (Route Stop 2)

Operator: John Smith (Pulping Operator)

Condition: High Bearing Vibration
Bearing Vibration: 7.2 mm/s (normal: &lt;6.0 mm/s)

Description:
Audible knocking sound from drive end bearing.
Pump still operating but needs attention.

Photos: 1 attached
Status: Open
Severity: Medium (manual classification)

Supervisor Review​

After the operator completes the round and data syncs, supervisors see observations flagged for review in the dashboard.

Observation Dashboard​

────────────────────────────────────
Observations Dashboard
────────────────────────────────────

⚠️ 3 open observations requiring review

[High Priority]
Observation #47 - Feed Pump P-404
High Bearing Vibration (7.2 mm/s)
Created: Today, 6:23 AM by John Smith
Status: Open

[Medium Priority]
Observation #48 - Cooling Tower CT-03
Algae Growth in Basin
Created: Today, 6:38 AM by John Smith
Status: Open

[Low Priority]
Observation #46 - Digester D-101
Temperature trending high (170°C)
Created: Yesterday, 6:10 AM by Sarah Johnson
Status: In Review
────────────────────────────────────

Supervisor Actions (Phase 1)​

When reviewing Observation #47 (Feed Pump P-404 high vibration), the supervisor can:

  1. View full details: See all readings, notes, photos, and trend history
  2. Add comments: "Scheduled maintenance for tomorrow's day shift. Monitor vibration until then."
  3. Change severity: Upgrade from Medium → High if condition worsens
  4. Update status:
    • Open → In Review (supervisor acknowledged)
    • In Review → Resolved (issue fixed)
    • In Review → Closed (false alarm or no action needed)
  5. Create work item: Generate maintenance work request (in Phase 1, this is manual; Phase 2 automates)

Phase 2 Enhancement Preview​

In Phase 2 (future), this workflow will be enhanced with:

  • Automatic severity classification based on rule engine
  • Alert notifications sent to supervisors and engineers
  • Triage workflows (acknowledge, escalate, assign)
  • Integration with work order systems for automated work requests

Common Observation Scenarios at Blueprint Paper Mill​

1. Out-of-Range Readings​

Scenario: Digester D-101 pressure reads 6.1 bar (above 5.8 bar threshold)

Observation created:

  • Title: "Digester D-101 - High Pressure"
  • Severity: High (pressure excursion can be dangerous)
  • Action: Supervisor reviews trend, determines if adjustment needed or transient spike

Outcome: Operator adjusts cooking liquor flow to bring pressure back to normal range. Observation closed with notes: "Pressure returned to 5.5 bar after flow adjustment."

2. Equipment Condition Issues​

Scenario: Felt Roll FR-07 shows visible wear on felt surface

Observation created:

  • Title: "Felt Roll FR-07 - Felt Surface Wear"
  • Severity: Medium
  • Photo: Close-up of worn area
  • Action: Supervisor schedules felt replacement during next planned downtime

Outcome: Maintenance work order created. Observation remains open until felt is replaced, then marked Resolved.

3. Noise and Vibration Anomalies​

Scenario: Air Compressor AC-12 has unusual vibration (operator checkbox: "Unusual vibration? Yes")

Observation created:

  • Title: "Air Compressor AC-12 - Unusual Vibration"
  • Severity: Medium
  • Notes: "Vibration reading within normal range (3.8 mm/s) but audible rattling noise from motor."
  • Action: Supervisor requests vibration analysis from maintenance team

Outcome: Maintenance identifies loose mounting bolt. Issue corrected same day. Observation closed.

Scenario: Over 5 consecutive days, Dryer Can DC-12 temperature has trended upward (88°C → 89°C → 91°C → 93°C → 95°C). All readings within normal range (85–95°C), but trend is concerning.

Observation created:

  • Title: "Dryer Can DC-12 - Upward Temperature Trend"
  • Severity: Low
  • Notes: "Temperature approaching upper limit. Recommend checking steam trap and condensate removal."
  • Action: Supervisor reviews trend graph, schedules inspection

Outcome: Blocked condensate line identified and cleared. Temperature drops back to 89°C. Observation closed.

Observation Metrics and Reporting​

Supervisors and engineers can generate reports on observation trends:

Example Reports​

Observations by Asset Type (Last 30 Days)

Asset TypeOpenIn ReviewResolvedClosed
Centrifugal Pump23125
Paper Machine Dryer0182
Rotary Equipment12154
Recovery Boiler0031

Observations by Severity (Last 30 Days)

  • Critical: 1
  • High: 5
  • Medium: 18
  • Low: 23

Most Common Observation Types

  1. High Vibration (14 observations)
  2. Temperature Out of Range (9 observations)
  3. Visible Leaks (7 observations)
  4. Unusual Noise (6 observations)

These reports help identify recurring issues and prioritize maintenance efforts.

Best Practices for Observations​

For Operators​

  1. Always add notes: Even if a reading is slightly out of range, explain what you observed (sounds, smells, visual cues)
  2. Take photos: Visual evidence is invaluable for supervisors and maintenance teams
  3. Be specific: "Loud knocking from drive end bearing" is better than "pump sounds bad"
  4. Don't ignore minor issues: Small problems become big problems if not documented early
  5. Trust your instincts: If something feels wrong, even if readings are normal, create an observation

For Supervisors​

  1. Review observations promptly: Address issues before they escalate
  2. Provide feedback to operators: Acknowledge good observations and guide improvements
  3. Track trends: Look for patterns across assets, shifts, or time periods
  4. Close observations with notes: Document what action was taken so future shifts can learn
  5. Prioritize by risk: Address safety and production-critical issues first

Verification​

After completing the observation workflow, verify:

  • ✅ Observations are created automatically for out-of-range readings
  • ✅ Operators can manually create observations for abnormal conditions
  • ✅ Observations include all relevant metadata (asset, timestamp, operator, readings, photos)
  • ✅ Supervisors can review, comment, and update observation status
  • ✅ Observation dashboard provides clear prioritization
  • ✅ Closed observations include notes explaining resolution

Congratulations!​

You've completed the Blueprint Paper Mill Tutorial. You now understand how to:

✅ Set up asset hierarchies and asset types for industrial facilities ✅ Design operator routes with structured route stops ✅ Capture readings on mobile devices in offline environments ✅ Handle abnormal conditions through observations ✅ Review and manage observations as a supervisor

What's Next?​

Continue exploring Cyzag Blueprint:

Or return to the main documentation:

Thank you for following the Blueprint Paper Mill tutorial! 🎉