Building Operational Maturity: Development of a Functional Process Control Plan

Operation of the treatment plants owned by Kansas City Missouri Water Services (WSD) was occurring on a compliance basis only, resulting in violations in water quality without an opportunity to remedy the situation before reporting had to occur. WSD worked with Burns & McDonnell to create a customized Process Control Plan (PCP), consisting of the Process Control Tool, where field and laboratory data is entered and the tool provides color-coded guidance; a Narrative PCP Document that provides guidance about implementing process changes; an Asset Status Tool designed to track the condition of critical treatment assets; and training and support for use of the PCP. Using the PCP, WSD was quickly able to identify equipment that had reached an unacceptable level of redundancy and act to restore equipment condition. Within the first three months of implementation, the Fishing River WWTP avoided a permit violation, demonstrating a clear reduction in organizational risk.