OTTO — How it works

Where handovers break down

OTTO turns scattered know-how into one shared map.

Your manuals and field notes each cover part of the job, and the rest lives in your engineers’ heads. Nothing links them, so every new colleague pieces together a different picture. OTTO connects your sources, the concepts behind them and the training built from them, ready to hand over.

What it costs youInconsistent understanding, gaps at handover and slower onboarding.

Your engineers are the first brain. Your manuals and notes are the second. Nothing connects the two.

Before: separate documents and unconnected knowledge

Second brainYour manuals and notes

Manuals
Field notes

Nothing connects them

First brainYour engineers

Start-up order
Why it trips
Who to call

With OTTO: sources, concepts and training units, connected

Sources

Concepts

Training units

I’m the third brain: one shared map that links your sources to what your team needs to learn.

OTTO trains new colleagues without the wait.

A new engineer takes three to four years to become an expert, and learns most of it by waiting for time with the engineer who already is one. OTTO turns that engineer’s walkthrough into a room each new colleague explores on their own, whenever they are ready.

What it costs youYears of your senior engineer’s time, and new colleagues who wait before they can work alone.

A new engineer takes three to four years to become an expert, waiting on your busiest engineer’s time.

Before: the walkthrough depends on your engineer being there

With OTTO: a training room where each new colleague explores on their own

Your engineer

New colleagues, waiting for the next walkthrough

I turn that walkthrough into a room they explore on their own, without the wait.

OTTO keeps what your experts know when they are not there.

What an experienced engineer checks first, and why, rarely makes it into the documents. It is out of reach when they are off shift, and it leaves with them when they retire. OTTO keeps it in training your expert has approved, so the answer is there on every shift.

What it costs youQuestions that wait for the next shift, and know-how that leaves for good at retirement.

When your expert is off shift or retires, what they know goes with them.

Before: the answer depends on your expert being there

With OTTO: the answer stays in training your expert approved

Your expert is

Your expert

Back on the next shift

Approved training

Day shift
Night shift
New crew

A crew on site asks

Why does the cooling pump trip on start-up?

Check the suction valve first. The pump trips on low flow when the valve is left closed after maintenance.

From training your expert approved

I keep what your expert approved, so the answer is there on every shift.

Try it on one task your engineers keep explaining.

Book a demo (opens in a new tab) Try a lesson

The four steps

Start with what you know

Bring your notes, documents and screenshots, plus a 45-minute walkthrough with your lead engineer. No polished manuals needed.

OTTOHARNESS

Plant Layers, Control, and Safety in a Batch Reactor Linebatch-reactor-line · demo course

Build the course

Step 1 · Your material

Sources

Everything OTTO reads to build this course. None of it needs polishing first.

Drop notes, PDFs, drawings or screenshots, or connect a folder

MD
reactor-line-wiki.mdWiki page · 2,140 words
Read
PDF
startup-procedure-rev-C.pdfProcedure · 14 pages
Read
PDF
pid-R101.pdfP&ID · 3 sheets
Read
IMG
hmi-screens/12 HMI screenshots
Read
XLS
pre-start-checklist.xlsxChecklist · 38 items
Read
REC
walkthrough-lead-engineer.mp4Walkthrough recording · 45 min
Reading

6 sourcesReady for the agents

Walkthrough with your lead engineer45 min

27:5445:00

What your engineer said

02:14“Before start-up I check the cooling pump suction valve first. It’s not in the procedure.”
17:40“If the SIS is bypassed, stop. Don’t trust what the HMI shows you here.”
27:31“This alarm trips on every cold start, and here is why.”

2 checksthat none of the documents mention

OTTO builds the course

OTTO turns your material into a course, connecting the key concepts and flagging anything that needs your expert’s attention.

OTTOHARNESS

Plant Layers, Control, and Safety in a Batch Reactor Linebatch-reactor-line · demo course

01Knowledge mapRound 1 · in review
02SyllabusWaiting
03RoomsWaiting

Phase 1 · Comprehend

Knowledge map

Control, safety and plant layers on a batch reactor line

For new engineers who know basic networking, not how control and safety are kept apart.

Concepts: 8
Prior models: 8
Sources: 6

7 declarative1 diagnostic

Sources read

reactor-line-wiki.md
startup-procedure-rev-C.pdf
pid-R101.pdf
hmi-screens/
pre-start-checklist.xlsx
walkthrough-lead-engineer.mp4

Click a concept to read its summary, prior model and coverage.

Concept8 CONCEPTS SHOWN

Layered physical layout Enterprise network Industrial DMZ Supervisory room, HMI, historian Physical distance as a defense PLC control logic SIS independence Reactor vessel, pump, valve

Concept · declarative

Safety instrumented system independence and proof testing

The SIS is separate from the PLC: its own sensors, logic and wiring, there only to force a safe state when a limit is crossed.

Prior model

“Safety and control are two modes of one shared controller.”

Wrong: bypassing one is not the same as bypassing the other.

Vocabulary

SIS
proof test
bypass
safe state

Drag a node to move it

Your expert reviews it

Your lead engineer reviews the course, adds what’s missing and approves it before anyone learns from it.

OTTOHARNESS

Plant Layers, Control, and Safety in a Batch Reactor Linebatch-reactor-line · demo course

01Knowledge mapApproved
02SyllabusRound 2 · in review
03RoomsWaiting

Gate · Round 2In review

Approve

Your lead engineerUnit 2 should open on a bypassed SIS, not normal operation. New hires need to see what a bypass looks like before the reading.
Syllabus agentSent back. The approved map stays as it is; the outline is rewritten with your note.
Round 2
Syllabus agentUnit 2 now opens on a bypassed SIS. One change, marked in the outline. Nothing else moved.

Send the harness a note…

Phase 2 · Outline

Three units, one hour

Trace the plant from office to vessel, and tell what PLC control and SIS safety each do.

Unit 1 · declarative · probe · 20 min

Walk the plant from office to vessel

Trace the reactor line as a physical chain of layers.

Layered physical layout
Enterprise network
Industrial DMZ

Unit 2 · declarative · scenario · 25 min

Why PLC control is not SIS safety

Changed in round 2 · from your note

Opens on ~~normal operation~~ a bypassed SIS, before the reading.

PLC control logic
SIS independence

Unit 3 · diagnostic · checkpoint · 15 min

Why distance and habits are defenses

Find where a shortcut removes a layer of protection.

Physical distance as a defense
Reactor vessel, pump, valve

Your team learns

Start with your own engineers. They explore the system, practise scenarios and explain their reasoning with OTTO before you plan a customer rollout.

← Lobby

UNIT 1 · SCENARIOWalk the plant from office to vessel

ImmersiveManipulate4 min

Course path01 / 05

01Scenario
02L1
03L2
04Hint-first tutor
05Checkpoint

Office workstation Boundary rack Operator console Process data recorder Control cabinets Reactor vessel Cooling pump Outfeed valve

Before anything is taught

This plant is a physical chain of spaces, not one control room with extra labels. I want you to point at the things that sit in order from office-side work to the place where the chemistry is touched.

Look around first. Then point.Continue →

Reactor line: office to process floor

Try it on one task your engineers keep explaining.

Book a demo (opens in a new tab) Try a lesson

How it works

Where handovers break down

OTTO turns scattered know-how into one shared map.

Before: separate documents and unconnected knowledge

With OTTO: sources, concepts and training units, connected

OTTO trains new colleagues without the wait.

Before: the walkthrough depends on your engineer being there

With OTTO: a training room where each new colleague explores on their own

OTTO keeps what your experts know when they are not there.

Before: the answer depends on your expert being there

With OTTO: the answer stays in training your expert approved

Try it on one task your engineers keep explaining.

The four steps

Start with what you know

Sources

OTTO builds the course

Knowledge map

Safety instrumented system independence and proof testing

Your expert reviews it

Three units, one hour

Walk the plant from office to vessel

Why PLC control is not SIS safety

Why distance and habits are defenses

Your team learns

Try it on one task your engineers keep explaining.

How the course gets built

A handover

Today: every new crew needs your engineer.

With OTTO: the know-how becomes training.