Operational Excellence (OE) is a difficult never-ending journey of continual improvement and a key goal for the global Chemical Process Industry (CPI).
Process Safety is a vital aspect of OE in the CPI. Because of the magnitude of process risks at operating sites, NO CPI company will be successful on the OE Journey without an unwavering commitment on the front lines to achieving Process Safety Excellence.
This workshop describes a strategic OE roadmap for achieving Process Safety Excellence on the front lines at operating sites that will also help sites meet many of their other OE objectives. It requires that sites:
- Move beyond just a regulatory compliance focus and adopt a rigorous risk based approach to process safety.
- Implement highly effective process risk management systems across engineering, operations, and maintenance functions to help ensure teams have the right information, at the right times, with the right competencies, resources, tools, and support to always make good process risk decisions.
- Build and sustain a High Reliability Organization (HRO) comprised of fully engaged Interdependent High Reliability Teams (HRTs) across all functions and at all levels from the site leadership team to front line teams.
Following this roadmap will greatly increase the likelihood that HRTs at CPI sites will GET IT RIGHT and prevent loss of containment incidents (Keep It in the Pipes and Vessels) and help move the CPI closer to achieving the CCPS vision of:
A world without process safety incidents.TM
- Understand why no CPI site will be successful on the OE Journey without achieving Process Safety Excellence.
- Remember the three aspects of the OE roadmap (listed above) for Process Safety Excellence and be committed to helping their team and site get there.
- Understand why HRTs cannot be successful without effective risk mgt. systems to help ensure teams always have the right information, at the right time, with the right competencies, tools, and resources to always make good process risk decisions.
- Recall various cultural characteristics or traits of a HRT (such as those for an ALERT CultureTM) that help maintain team effectiveness.
- Understand that HRTs must maintain an ongoing focus on the Critical 5CsTM for success and keep asking three questions every year.
- Identify several priority topics related to process safety knowledge/competencies for improvement objectives in the coming year.*
- Using a list of examples provided of Conduct of Operations activities, identify several priority topics for team improvement objectives in the coming year.
*Note: This workshop will not be a considered a success unless there are continuing follow up actions taken AFTER the workshop by every attendee to help improve team Culture, Competencies, Compliance with Standards and Conduct of Operations. Examples of several dozen improvement objectives related to the workshop topics listed in the agenda below are provided for attendees to choose from at the end of the workshop and for future years.
This workshop helps engage/align everyone at a site on the Process Safety Excellence Journey and typically includes:
- Control room and field operators, maintenance crafts specialists, and their direct supervisors
- Site process engineers as well as reliability or maintenance engineers and project engineers
- Site leaders of engineering, manufacturing operations, and maintenance functions
- Those from other site support functions such as EHS, Quality, HR, and Procurement.
Daily Schedule: 8:30 AM to ~3:30 PM (two 10-min breaks in AM before lunch & one 10-min break in PM)
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