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This workshop provides a strategy/roadmap for the Process Safety Excellence journey for front line teams to increase the likelihood of teams making good process safety risk decisions--“Get It Right”; that keeps equipment and safeguards reliable and prevents Loss of Containment (keep it in the pipes and vessels). Process Safety Excellence is a key requirement for Operational Excellence (OE) across chemical process industry (CPI) production sites globally, and like OE, requires a strategy to build/sustain a High Reliability Organization (HRO) comprised of interdependent High Reliability Teams (HRTs) across all functions and at all levels from the site leadership team to front line shifts with all focused on the Critical 5CsTM and communicating/cooperating to make good risk decisions.
(This course does not specifically focus on the twenty Risk Based Process Safety elements. For a detailed course, we recommend our flagship course, Process Safety Boot Camp.)
This workshop is intended to get those on the front lines actively engaged and committed to the journey to excellence. Participants should include site functional leaders (from engineering, operations, maintenance) and selected staff members from their organizations, shift and area supervisors, control room operators, field operators, maintenance crafts specialists, and process engineers and reliability engineers supporting operations and maintenance activities.
Day One: 8:30 AM to ~3:30 PM (two 10-min breaks in AM before lunch & one 10-min break in PM)
Segment Topics
0 Overview of Workshop (includes greeting by Site Leader/Host)
1 Interdependent HRTs Required to GET IT RIGHT -- KEEP ASKING WHAT-IF NO SILOS
2 ALL Engaged from SITE LEADERSHIP to the FRONT LINES in Managing Risks to Prevent Incidents
NO PASSENGERS SPEAK UP NO FACADES GO BEYOND COMPLIANCE
3 An ALERT CultureTM -- Sustained by Effective Communication & Trust SPEAK UP NO BULLYING
Lunch Break at Approximately Noon (30 min)
3 Complete Segment 3
4 Competencies -- Many Required Including Basic Risk & Process Safety Concepts
5 Competencies -- Remember Incident Stories, Understand Scenarios/Safeguards/Periods of Higher Vulnerability & KEEP ASKING WHAT-IF Maintain Appropriate Sense of Vulnerability
Day Two: 8:30 AM to ~3:30 PM (two 10-min breaks in AM before lunch & one 10-min break in PM)
Segment Topics
5 Complete Segment 5
6 Conduct of Ops -- HRTs Committed to Minimize Drift from Standards with Roles Defined to KEEP EQUIPMENT & SAFEGUARDS RELIABLE
7 Conduct of Ops -- Everyone Ever Vigilant for Incident Warning Signs
Lunch Break at Approximately Noon (30 min)
7 Complete Segment 7
8 Competencies -- Understand & Manage Human Factors Challenges
9 A CALL TO ACTION -- Continual Learning & SMART Objectives Needed for a Successful Journey
Wrap Up/Course Evaluation Form Completion/Adjourn at ~3:30 PM
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