Our Process Safety Metrics and the Learning Journey

Transcription

1 1 Our Process Safety Metrics and the Learning Journey 02/10/2018 CCPS Asia Pacific Regional TSC Meeting, Singapore Lelwyn D Souza VP Supply Chain AP Bala Raman 8 th September 2017 Process Safety Manager, Ecolab - Asia Pacific

2 Presentation Overview ECOLAB- Our Purpose and values,, Where we see Risks? What causes these Risks? Managing down the Risks. Sustaining the gain! 2

3 SAFETY EVERYWHERE. 3

4 Global Company, Global Reach Founded in 1923 Headquartered in St. Paul, MN 48,000+ Total employees FORTUNE 500 COMPANY Serving customers in 171 countries 1 million Customer Locations 115 Total manufacturing facilities $13 billion in annual sales 4

5 We are Set Up to Support and Supply our Customers Globally 19 technology centers 25,200 sales-andservice representatives countries 115 plants 48,000 employees more than 220 warehouses 5

6 Ecolab: Providing + Protecting What s Vital Clean Water Safe Food Abundant Energy Healthy Environments 6

7 We Develop the Best Business Solutions by Solving Real-world Problems Nalco EC Ecolab Champion 1,600 Scientists 6,700 Patents 11 Global Research Centers Bangkok Campinas Dusseldorf Eagan Greensboro Naperville Pune Shanghai 7 8 Regional Technical Centers Singapore Sugar Land Sydney Tokyo Monheim

8 Every Year, Ecolab Helps: Meet 45% of the global demand for petroleum products Produce MORE THAN A QUARTER Fuel 604 BILLION cars of the world s processed food = 694 BILLION pounds a year Serve 45 BILLION meals Produce of the global processed milk supply 42% Generate 22% 40% of the world s power of all nuclear power 1 BILLION+ Clean hotel rooms 8

9 SH&E Program Maps to Ecolab Needs Profitable Ethical, Honest Customer Focused Complex Growth Modes Via acquisition Organic Turnover Cost Conscious Tight on resources Risk Based Decisions 9

10 CCPS as Basis and Guidance Align with Ecolab Corporate Culture Fit Company Profile Risk Based Quantifiable Map to Industry & Ecolab Industry Benchmark Basis for Ecolab Program Latest : Ecolab and AIChE exploring Partnership Opportunities - DOING A WORLD OF GOOD CAMPAIGN 10

11 A Good Process Safety Program Key Features: Working safely is a core value Resources dedicated for identifying, understanding, and mitigating risks Promotes dialog between all levels of the organization to consider all perspectives Emphasizes continuous improvement above just meeting compliance 11

12 Does the Program work? Yes!- But slower BEST-ever performance Continued, consistent improvement Part of SHE Management System (SMS) Continue the momentum with more granularity. #1 Requirement Senior Leadership Champions 12

13 Data Analysis and Improvement Plan Asia pacific Performance Profile (Loss Tree) 2019 Focus Area Leadership engagement and Knowledge Level 1 Level 2 base development Programs. Critical Equipment Std implementation and Timely execution of PM Plans Comply Global Programs / Standards. (MOC, Flammability, Incompatibility, etc) Tech Visits (Quick Risk Predictions) and HIRA. Level 3 MI : 57% 13

14 TPM (TOTAL PRODUCTIVE MAINTENANCE) IS PART OF LIFE 14

15 Ecolab Risk Tolerance Criteria Risk = Likelihood * Severity Establishes when action is mandatory to reduce risk and to prioritize. Aligns with industry practice and Ecolab s performance goals As and Bs- Not Tolerated 15

16 What s Our Risk? What s the Hazard? What s the Risk? What s the Priority? What (risk are we dealing with) Business related Volume Location Chemistry Performance Why is the risk there Screening (SLRA) Likelihood (data) Intervention (performance based) Risk Matrix Spider (profile) Charts 16 Setting focus / priority Hazard Recognition Flammables Unplanned Mixing /Incompatibility Open Ends Metrics SMS HIRA

17 Evaluating Risk, Identifying Causes-Global Where s the risk? Any Critical Needs? What s the Priority? Public Data Flammables Taproot 5 Whys Chemical Incompatibility Leverage Learning Open Ends Root Causes 80:20 Hit the Big Ones Critical Equipment 17

18 Example Red List & Reactivity Outcomes Table Red List / Reactivity Matrix Tool developed to mitigate risk of inadvertent mixing of incompatible materials Increase understanding of which materials are incompatible and potential results of reactions Assists in the organization of storage / warehousing and design of manufacturing processes 18

19 PSE Metrics in Logistics Area- New 19

20 Critical Equipment Program via PM Pillar Committed Effort 20

21 PS Tier 3 / Loss Campaign- Asia Pacific (Tactical) Leadership- Encourage campaign momentum Streamline into Gemba walk, Safety Committee / CAPA process Analyse data to address systemic gaps 21

22 Ecolab Risk Profile Tool Organized questionnaire with scoring system that identifies gaps in Process Safety Systems Measures against Industry Best Practice Compare region, roles, etc. Identifies areas of strength Identifies where to upgrade skills 22

23 Sustain: Reward& Recognition Leading metrics Award Spot the Risk Poster contest 1 Year Zero TRIR, Tier 1 PSE Award 5 Year Zero Award Open Ends contest 23

24 Sustain: Integrating into Culture Plant Manager Qualifications SHE Program Procedures Critical Equipment (SHE Elements) MI program Operations Maintenance Leverage Engineering Human Resources Standards Practices Specifications Blue Books Reward & recognition Training Roles & Responsibilities 24

25 Sustain: Training Framework 25

26 Sustain: Accountability Example: Plant Managers Qualification 26

27 Ecolab Standards Development Flow 27

28 What s Working well so far, 50% Redux After 2 years 1. Process Safety is Integral part of Business 2. Agree on Acceptable Risk 3. Identify, Analyze and Prioritize Risks 4. Plan & Phase the Implementation 5. Stay on the Course 6. Engagement is the key 28

29 QUESTIONS? & THANK YOU. 29