Reports of accidental releases involving hazardous chemicals at fixed facilities in the US reached all-time highs during the 2023 fiscal year. For these reasons and others, process safety improvements are top of mind in the industrial sector. So how can organizations prioritize limited resources, people-power, and time to take action? This article explores the following topics:
Rising Incidents and the Importance of Safety: Reports of process safety incidents have been increasing, with a 51% rise in reportable incidents in 2023, including significant increases in injuries (11%) and deaths (78%), highlighting the urgent need for improved process safety practices.
Leadership Commitment: Strong leadership is essential for a robust process safety culture. Senior management must prioritize safety over productivity, dedicating resources, time, and direction to safety initiatives to avoid incidents that could cause serious harm and financial losses.
Real-World Data Application: Organizations should implement a structured approach like the PDCA (Plan-Do-Check-Act) cycle to assess process safety systems, execute improvements, and continuously monitor outcomes using real-world data to drive safety progress.
Employee Empowerment: Engaging and empowering employees at all levels, especially those interested in becoming subject matter experts (SMEs), fosters a more inclusive safety culture. Educating staff on process safety can bridge knowledge gaps and accelerate improvement efforts.
Start Small for Bigger Wins: Focusing on smaller, more manageable process safety improvements can lead to early successes. These wins help organizations build momentum and prepare for tackling more complex safety challenges in the future.
Continuous Improvement (CI) System: Utilizing continuous improvement methodologies, like Kaizen and Lean Manufacturing, helps organizations make incremental changes that enhance safety and operational efficiency. Choosing a suitable CI approach and sticking with it is key to long-term success.
Focus on Culture: A high-performing process safety program relies on a culture of continuous improvement, employee engagement, and early wins. Starting small and sustaining progress is critical to enhancing both safety and overall operational performance.
by Judith Leslie, CFSE, CSP, CCPSC, senior principal specialist with aeSolutions.
Read the full article here: Enhancing Process Safety: Five Tips to Build a Better System (Powderbulksolids.com)
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