Improving gypsum production quality through human factors, real-time monitoring and standardized operating procedures in the dewatering system

Purpose This study aims to examine how human factors (HF), real-time monitoring and standardized operating procedures can improve quality and reliability in the gypsum dewatering system of a chemical plant experiencing frequent unplanned shutdowns. Design/methodology/approach The quality improvement through ergonomics (QUITE) methodology was applied through operator interviews, plant observations, value stream mapping, critical-to-quality analysis, maintenance records, Pareto analysis, Ishikawa analysis and five-Whys analysis. The assessment identified four contributors to unplanned shutdowns: vacuum and conveyor belt failures, inadequate preventive maintenance and maintenance strategy, difficulty in maintaining stable process operation and delayed operator responses. The implemented interventions were digital control system (DCS)-based real-time monitoring and standardized operating procedures. Findings Breakdown failures decreased by 56%, from 80 failures in the fourth quarter of the baseline year to 35 failures in the same quarter of the following year. The interventions improved system visibility, operator responsiveness, work standardization and process stability. Originality/value The study extends prior QUITE applications to gypsum dewatering by integrating human factors assessment with DCS-based monitoring and standard operating procedure implementation.