Synergy Journey Phase 2 Process Safety and Culture Assessment
As a major producer of polypropylene with a strong safety performance record, the client undertook a process safety management and safety culture assessment as the first step in creating synergy around safety and driving growth. Phase 1 of the project resulted in a multi-year transformation roadmap designed to implement four key initiatives.
The Challenge
Once recognised the following four initiatives for improvement, the company engaged dss+ to ensure effective implementation of their roadmap:
- Risk containment to mitigate catastrophic incidents
- Development of leadership and frontline operational risk management competencies
- Technical and capability enhancement around process safety management
- Governance, integration, and accountability for strengthening safe operations
The dss+ team collaborated with leadership and frontline personnel to develop capabilities and improve safety culture across the operation.
The dss+ Approach
The transformation roadmap was divided into three stages , allowing for gradual mindset shifts and growth in the capacity of site personnel.
1: Risk Mindset
Ensuring that risk thinking is always top of mind for site management through:
- Governance to monitor risk status and program progress
- Risk containment of selected top risks—demonstrating tangible impacts and safeguarding the transformation by preventing catastrophic incidents
- Process safety competency management for key personnel, including development of competency requirements and baseline assessment
2: Risk System
- Establishing a process safety management framework and manual
- Achieving safe operation through training and coaching PSM subcommittees to identify gaps and develop and deploy fit-for-purpose procedures to close them
3: Risk Thinking
- Embedding risk thinking among frontline personnel through hands-on coaching and empowering them to proactively own the risks
Impact
Advances were seen across the organisation, including:
- Five top process safety risks and one top occupational safety risk were contained in year one and a Risk Containment Playbook was created to ensure continued efforts
- A Governance for PSM Committee, PSM Element Subcommittee, and Risk Containment Subcommittee were established
- Process safety indicators were identified and monitoring set up
- A tailored Process Safety Management Manual with elements and expectations was developed
- Procedures were developed and subcommittee members received coaching around process safety information, change management, permit to work, emergency preparedness, and life saving rules
- More than 100 members of site leadership and frontline personnel received coaching tailored to their roles in the transformation program
Leadership Perspective: Voice from Senior Manager
“Changes emerged as a result of several new initiatives. Not all of them originated from this program, however, dss+ helped shape leaders’ mindsets in how they think about initiatives and the decisions they make.”
- Senior Manager
Discover all 2 phases of the project.
Phase 1: Process Safety and Culture Assessment