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Creating Operator Rounds

In this section, you'll learn how to design operator routes for Blueprint Paper Mill. These routes guide operators through structured equipment inspections, ensuring consistent data capture across all shifts.

What is an Operator Round?​

An operator round is a structured inspection route through your facility where operators:

  • Visit specific assets in a defined sequence
  • Record readings against pre-configured asset attributes
  • Capture photos of equipment conditions
  • Add free-text observations for abnormal conditions
  • Document the time, date, and operator for each reading

Designing Routes​

For Blueprint Paper Mill, we'll create three routes covering different areas and shift responsibilities:

Round 1: Morning Shift - Pulping & Utilities​

Frequency: Daily, start of morning shift (6:00 AM) Duration: Approximately 45 minutes Purpose: Verify critical equipment in pulping and utilities is operating normally

Round 2: Paper Machine Line Inspection​

Frequency: Every 2 hours during production Duration: Approximately 20 minutes Purpose: Monitor paper machine condition and quality parameters

Round 3: End of Shift - Full Mill Walkthrough​

Frequency: End of each shift (6:00 AM, 2:00 PM, 10:00 PM) Duration: Approximately 60 minutes Purpose: Comprehensive check before shift handover

Example: Morning Shift - Pulping & Utilities Round​

Let's design the Morning Shift - Pulping & Utilities round in detail.

Step 1: Define Round Metadata​

  • Name: Morning Shift - Pulping & Utilities
  • Description: Daily inspection of critical pulping equipment and utility systems to verify normal startup conditions
  • Estimated Duration: 45 minutes
  • Assigned Roles: Pulping Operator, Utility Operator
  • Frequency: Once per day, beginning of morning shift

Step 2: Define Route Stop Sequence​

The round follows a logical route through the facility:

Route Stop 1: Digester D-101​

Location: Unit A – Pulping, basement level Expected connectivity: Poor (basement)

Readings to capture:

  • Cooking Temperature (°C) – numeric input
  • Digester Pressure (bar) – numeric input
  • H-Factor – numeric input
  • White Liquor Flow (L/min) – numeric input
  • Chip Level (%) – numeric input
  • Unusual noise or odor? – yes/no checkbox
  • Photo – equipment photo (optional)
  • Notes – free text observations

Normal ranges reminder (displayed to operator):

  • Temperature: 165–172 °C
  • Pressure: 5.2–5.8 bar

Route Stop 2: Feed Pump P-404​

Location: Unit A – Pulping, pump room Expected connectivity: Poor

Readings to capture:

  • Discharge Pressure (bar) – numeric input
  • Motor Amperage (A) – numeric input
  • Bearing Vibration (mm/s) – numeric input
  • Seal Temperature (°C) – numeric input
  • Visible leaks? – yes/no checkbox
  • Photo – pump seal area (if leaks detected)
  • Notes – free text observations

Route Stop 3: Black Liquor Tank BL-02​

Location: Unit A – Pulping, ground level Expected connectivity: Good

Readings to capture:

  • Tank Level (%) – numeric input
  • Liquor Temperature (°C) – numeric input
  • Photo – level gauge (optional)
  • Notes – free text observations

Route Stop 4: Steam Boiler B-01​

Location: Unit D – Utilities, boiler house Expected connectivity: Good

Readings to capture:

  • Steam Pressure (bar) – numeric input
  • Flue Gas Temperature (°C) – numeric input
  • Feedwater Conductivity (µS/cm) – numeric input
  • Drum Level (%) – numeric input
  • Flame pattern normal? – yes/no checkbox
  • Photo – flame observation port (optional)
  • Notes – free text observations

Route Stop 5: Air Compressor AC-12​

Location: Unit D – Utilities, compressor room Expected connectivity: Good

Readings to capture:

  • Discharge Pressure (bar) – numeric input
  • Discharge Temperature (°C) – numeric input
  • Motor Amperage (A) – numeric input
  • Oil Level – dropdown (OK / Low / Check Required)
  • Unusual vibration? – yes/no checkbox
  • Photo – oil sight glass (optional)
  • Notes – free text observations

Route Stop 6: Cooling Tower CT-03​

Location: Unit D – Utilities, outside Expected connectivity: Good

Readings to capture:

  • Fan Vibration (mm/s) – numeric input
  • Water Temperature (°C) – numeric input
  • Fan Noise Level – dropdown (Normal / Abnormal)
  • Visible algae growth? – yes/no checkbox
  • Photo – tower basin (optional)
  • Notes – free text observations

Step 3: Configure Round Behavior​

Offline support: Enabled (critical for basement areas) Auto-sync: When connectivity returns Require all route stops: No (operator can skip if equipment is down) Photo requirements: Optional (required only if abnormal condition) Completion signature: Required

Step 4: Define Alerts and Follow-up Actions​

Configure the round to trigger alerts or work items when:

  • Any reading falls outside normal range → Create observation
  • Operator selects "yes" for abnormal checkboxes → Create observation
  • Operator adds photo with notes → Flag for supervisor review
  • Round not completed within 60 minutes of start → Send reminder

Example: Paper Machine Line Inspection Round​

This round runs every 2 hours during production to monitor paper machine health.

Route Stop Sequence​

  1. Headbox HB-01: Stock consistency, flow rate, air content
  2. Press Section Drive Motor PM-03: Amperage, temperature, vibration
  3. Felt Roll FR-07: Vibration, temperature, visual condition
  4. Dryer Can DC-12: Surface temperature, steam pressure, condensate temperature

Duration: ~20 minutes Offline support: Enabled Frequency: Every 2 hours during production

Example: End of Shift - Full Mill Walkthrough​

Comprehensive round covering all units before shift handover.

Route Stop Sequence​

  1. All assets from Unit A – Pulping (Digester, pumps, tanks)
  2. All assets from Unit B – Screening & Cleaning (Screen, cleaner pump)
  3. All assets from Unit C – Paper Machine Line (Headbox, dryers, motors, rolls)
  4. All assets from Unit D – Utilities (Boiler, compressors, cooling tower)

Duration: ~60 minutes Offline support: Enabled Completion required: Yes (mandatory before shift ends) Handover notes: Operator must add summary notes for incoming shift

Best Practices for Round Design​

1. Logical Routing​

Order route stops to minimize walking distance and follow natural workflow:

  • Start at one end of the facility
  • Work systematically through areas
  • End near control room or shift handover location

2. Realistic Time Estimates​

Consider:

  • Walking time between route stops
  • Time to take readings (15–30 seconds per reading)
  • Time for photos and notes (1–2 minutes if needed)
  • Potential delays (waiting for equipment access, PPE requirements)

3. Connectivity Planning​

Identify areas with poor connectivity:

  • Basements, pipe chases, equipment rooms
  • Outdoor locations far from buildings
  • Areas with RF shielding or metal structures

Ensure rounds work seamlessly offline in these areas.

4. Shift-Appropriate Rounds​

Design rounds that match shift responsibilities:

  • Morning shift: Focus on startup checks and overnight issues
  • Day shift: Detailed inspections and maintenance follow-up
  • Evening shift: Production monitoring and shutdown preparation
  • Night shift: Basic operational checks and safety verification

5. Balance Detail vs. Speed​

Too many readings slow operators down; too few miss critical data:

  • Include only readings that inform decisions or track trends
  • Use yes/no checkboxes for quick assessments
  • Reserve detailed readings for critical or high-risk equipment

Verification​

After creating routes, verify:

  • ✅ Route stops follow a logical physical route
  • ✅ All critical assets are included in at least one route
  • ✅ Normal operating ranges are displayed at each route stop
  • ✅ Offline support is enabled for areas with poor connectivity
  • ✅ Estimated duration matches realistic completion time
  • ✅ Route assignments match shift responsibilities

Next Steps​

Now that your routes are designed, you're ready to see them in action. Continue to Capturing Readings to learn how operators use Cyzag Blueprint on mobile devices to complete rounds.