The Golden Batch tool is a digital tool built and developed by Yara for Yara fertiliser plants. The basic idea of the tool is to digitise binders and notebooks with historical references of good production, i.e. Golden Batches. The tool provides a user-friendly way to search for and use previous production periods to follow up current production. It also continuously monitors the plant, ensuring the best production periods are always captured and stored for the future.
Central to the tool’s development is the programmatic definition of what qualifies as a ‘good production.’ This definition serves a dual purpose: firstly, identifying Golden Batches based on historical datasets, and secondly, continuously monitoring ongoing plant operations to identify and optimise for superior production periods. This approach mitigates reliance on subjective assessments of production quality, thereby enhancing standardisation, troubleshooting capabilities, and aiding in the training of new personnel.
However, the adoption of this transformative tool is not without its challenges. It demands substantial time and effort for training and integration. Nevertheless, this investment is imperative for unlocking the full potential of the tool. Presently, the tool has been successfully implemented in six NPK plants, with an observable trend of high user adoption overall, but with challenges in some plants. A post-project review conducted on the initial plant wherein the tool was deployed revealed a significant increase in the production rate after the tool’s implementation.
The Golden Batch tool is not a static solution; it is a dynamic tool that emphasises continuous improvement. The application undergoes evolutionary adaptations responsive to user needs, innovative ideas, and constructive feedback.