Domain : Manufacturing : Oils and Gases Context : In Air separation unit the process is maximum hazardous and very sensitive, always on trigger of process failure(Even in stable condition) even due to small errors and internal noise or external noise, this leads to high risk of safety to the Employee, Environment, Surrounding and assets this is safety concerns due to critical characteristic of products and process, sensitive operations of high pressure and temperatures and other parameters. also the On supply to On site customer is so critical it’s mandatory to be on top and vigilant in managing the process and plant consistently. Intent : The intent was to build stable Artificial Intelligence Predictive and control Model to ensure high ‘’Safety and customer service and performance’’ even from start of the process and then maintaining the End to End stable process parameters which leads to better temperature and flow distribution and pressure ratios to attain the desired cryogenic product out put. HOW and what considerations are made to build the below AI Model : AI has emerged has assistant, guide and consultant to review the present process conditions been operated based on real online data and analyse that in real time in few seconds and make the suitable decision to the bring the process bias, to reflect the process output the intended output for highly safe and to ensure high Safety and customer service and performance To build the trust on AI Model by the operator, process operation team we have involved then in the design, considered all technical details, design conditions of the End to End process Lets say from high capacity Air compressors and high capacity Turbines and communication flow to End to End stake holders and taken all suggestions that would call a need for inclusion in the AI Model as Operators and Process Owners being the face of the process and close to reality they know the process very well. Major methodology Executed. Risk analysis, Brain Storming, Suitable best considerations were made, solutions were identified & Evaluation. The solution was built, tested. Simulations were done with involvement of Shop floor operators and Process Owners Ensured trust building and empowerment to Shop floor operators and Process Owners by involving them in End to End development and till Go-Live Commissioning. Control Measures taken to sustain the implementation and developed Trust While on implementation we had the question ‘’How should responsibility be defined’’ to ensure the recommendations from AI predictive model is followed and ignored, what necessary actions to be taken and by whom, who is responsible, accountable, Concerned and Informed. AI has emerged has assistant, guide and consultant to review the present process conditions been operated based on real online data and analyse that in real time in few seconds and make the suitable decision to the bring the process bias, to reflect the process output the intended output. But the question remains is if ‘’The AI’s recommendation is followed, and things go wrong?’’ How should the plan of action to be taken & who should be responsible for it, What could be best RACI ? & The AI’s recommendation is ignored, and things go wrong? As AI Model doesn’t provide a definitive Fix, it’s not a solution or application which is not affected by any External or Internal Factor and it’s not one time installed or invested and forgotten. It’s to be tracked and treated as element of evolution and a process of Continuous improvement and evolution really holds good for this to assure system should not fall behind when the AI solution keeps merging with new horizons. Below Structured approach was deployed : Tools and System : Below tools and systems were implemented to find the true structure approach so that team is not lost with lots of information, change and new updates and would help to follow the simplified necessary steps, eliminate Non value addition, avoid confusions, blame, or risk-avoidance behaviour or perform the activities with risk. System & Standards : RACI Matrix : RACI Matrix was defined and developed to ensure the structured flow to take the actions, by whom, who is responsible, accountable, Concerned and Informed. This was evaluated with cross functional heads and team members, communicated end to end on RACI so that all are aware and aligned. SOP : Standard Operating Procedure : SOP revisions with new versions : Updated Step by Step SOP are created for each process lines and considered new operating conditions with AI predictive Model mentioning, below important detailed needs are incorporated. When to take actions when things can go wrong with AI Proposal and AI Proposals are Ignored When to Ignore the AI recommendation ? When to override and take the control in manual ? How to treat, What actions to be taken when the Alarm given by AI predictive system ? What to actions to take When the sudden and unexpected internal or External Noise appeared in the system ensure ? Standards : Standards were created Standard Documents creation and approvals as per approval hierarchy like creator, reviewer and validation, approver Review and revisions for new versions with updates so that change is tracked. Tools & Systems : ONE DOC : Application/Software to manage the Standards was implemented, with ‘’Definitive Identification Number’’ this has ensured the live availability of right standards documents in the Library to the Process Owners Alert system & Action Log Books & Reporting : Implemented specific action Log book via Online Share point action log book, in which Operators and Process Owners mention the alarm, deviation from AI system and what actions were taken, remarks for the difficulties faced, also the need of further evolution in the AI program to Nullify the error or Noise,, or to mention the Idea if any ? Share point (Online) : Online Share point action log book, in which Operators and Process Owners mention the alarm, deviation from AI system and what actions were taken, remarks for the difficulties faced, also the need of further evolution in the AI program to Nullify the error or Noise,, or to mention the Idea if any ? MOC : Management of Change Management of Change is ensured and given a clarity and facilitated the Live updated Document at any point of time, this has helped to avoid confusions, blame, or risk-avoidance behaviour. Conclusion : AI Model provides solutions which is probably close the stable process as needed by the standards but there are high chances also that AI suggestions needs to be thought about and questioned to avoid the failures due to possible wrong suggestions provided by AI by not taking Noise in to considerations or additional necessary prompt in it’s background verification and suggestions. So End to End thought out Structured process is to be implemented as mentioned above to ensure no confusions, mistake, blame game, to held accountable and responsible, to keep the risk behaviour in control by the AI system also by human.