Guidelines for Integrating Management Systems and Metrics to Improve Process Safety Performance

This book combines the synergies between performance improvement systems to help ensure safe and reliable operations, streamline procedures and cross-system auditing, and supporting regulatory and corporate compliance requirements. Many metrics are common to more than one area, such that a well-designed and implemented integrated management system will reduce the load on the Process Safety, SHE, Security and Quality groups, and improve manufacturing efficiency and customer satisfaction. Systems to improve performance include: process safety; traditional safety, health and environment; and, product quality. Chapters include: Integrating Framework; Securing Support & Preparing for Implementation; Establishing Common Risk Management Systems - How to Integrate PSM into Other EH; Testing Implementation Approach; Developing and Agreeing on Metrics; Management Review; Tracking Integration Progress and Measuring Performance; Continuous Improvement; Communication of Results to Different Stakeholders; Case Studies; and Examples for Industry

List of Figures xi List of Tables xv Acronyms and Abbreviations xvii Glossary xix Acknowledgments xxv Preface xxvii 1 INTRODUCTION 1 1.1 The Need for Integration 1 1.2 The Purpose of this Guideline 4 1.3 The Scope of this Guideline 4 1.4 The Approach used in this Guideline 4 1.5 How Established Models can be used in Integrated Systems 8 1.6 Exclusions to the Scope 9 1.7 Key Audience for this Guideline 9 1.8 Some Recent Advances in Process Safety Metrics 10 2 SECURE LEADERSHIP SUPPORT ACROSS GROUPS 11 2.1 The Need for Securing Support 11 2.2 Securing Support to Optimize Resource Allocation 14 2.3 Developing a Preliminary Plan 16 2.4 The Importance of a Safety Culture 23 2.5 Identifying Stakeholders 24 2.6 Sharing Resources across Groups 27 2.7 The Case for a SHEQ&S program 27 2.8 Surveying for Competency Gaps 28 3 EVALUATE HAZARDS AND RISKS ACROSS GROUPS 31 3.1 The Need for Evaluating Hazards and Risks 31 3.2 Identifying and Prioritizing Key Processes and Risks 32 3.3 Selecting Potential Metrics 33 3.4 Focusing on Process Safety Performance 35 3.5 Re-evaluating Metrics for Continuous Improvement 35 3.6 Examples of Performance Effects across SHEQ&S Groups 38 4 IDENTIFY COMMON METRICS ACROSS GROUPS 41 4.1 The Need for Identifying Common Metrics 41 4.2 Define the System Integration Process 43 4.3 Identify the Program Requirements 43 4.4 Develop the Program 43 4.5 Identify Overlapping Metrics 46 4.6 Prioritize the Program Installation 66 4.7 Document the Program Baseline 72 4.8 Continuous Improvements 73 4.9 Some Management System Assessment Tools 73 4.10 Other Metrics Worth Considering 82 5 IMPLEMENT THE SHEQ&S PROGRAM 83 5.1 The Need for Proper Implementation 86 5.2 How to Apply the Plan, Do, Check, Act (PDCA) Approach 86 5.3 Piloting the SHEQ&S program 95 5.4 Communication 103 6 MONITOR THE SHEQ&S PROGRAM PERFORMANCE 105 6.1 The Need for Reviewing and Assessing Program Performance 106 6.2 How to Reinforce the Integrated Framework 108 6.3 How to Use Management Reviews to Respond to Gaps 108 6.4 How to Engage Leadership 109 6.5 The Roadmap and Process Improvement Plan 110 6.6 Auditing and Verifying the Program 110 6.7 Tracking Corrective Actions 111 6.8 Statistical Methods and Tools 112 6.9 Capturing Early Success 114 6.10 Improving Performance in All SHEQ&S Management Systems 115 6.11 How and When to Communicate the Information 115 6.12 Obtaining Stakeholder Feedback 118 6.13 Metric Communication Examples 119 7 IMPLEMENT CHANGES TO THE SHEQ&S PROGRAM 121 7.1 The Need for Continuous Improvement 122 7.2 Ensuring Management Responsibility 122 7.3 Addressing Non-Conformities 122 7.4 Using Statistical Methods 126 8 EXAMPLES FROM INDUSTRY 127 8.1 Case Studies 129 8.2 Examples of the SHEQ&S program 129 APPENDIX A: REFERENCE LISTS FOR GLOBAL PROCESS SAFETY LEGISLATION AND SHEQ&S ORGANIZATIONS 131 APPENDIX B: RECENT ADVANCES IN PROCESS SAFETY METRICS 139 APPENDIX C: POTENTIAL ANSWERS DESCRIBING THE NEED FOR SECURING SUPPORT 145 APPENDIX D: DETAILED CASE STUDY FOR DESIGNING AND IMPLEMENTING A SHEQ&S PROGRAM 147 APPENDIX E: EQUIPMENT INTEGRITY IN THE EQUIPMENT LIFE CYCLE 158 APPENDIX F: THE SHEQ&S MANAGEMENT SYSTEM MAPPING SURVEY 160 APPENDIX G: THE PROCESS SAFETY PERSONNEL COMPETENCY SURVEY 167 REFERENCES 179 INDEX 185