4-CCPS中國安全領(lǐng)導(dǎo)力和管理培訓(xùn)之管理角色和責(zé)任ppt課件

1、1Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersManagementRoles and ResponsibilitiesIndividual Roles and ResponsibilitiesThe best organizations take the time to write them downClarifies gray areas to all employeesEliminates many oversights when peopl

2、e change rolesServes as a basis for re-mapping roles to other positions when making an organizational changeCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersThe Role of PS Steering CommitteesPlace these where you have significant hazards, and protectiv

3、e layers that need high level of integrity.RoleApprove certain changes as part of the MOC processAsk a lot of questions. Use the collective experience of the team to uncover areas of weakness in well intended changes.Copyright 2021 Center for Chemical Process Safety of the American Institute of Chem

4、ical Engineers4Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersManagementProcess Safety Competency, Training, and CertificationLodi, New Jersey - 1995Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersCont

5、ributing FactorsTolling operationInadequate communication of hazards between Technic and Napp (toller)No PHA conductedBlender inappropriate for the processSOPs and Training less than adequateLack of understanding of consequences with regard to emergency action to off load blenderCopyright 2021 Cente

6、r for Chemical Process Safety of the American Institute of Chemical EngineersProcess Safety Competency (1)Know the hazards of the processKnow where the process can pose a threat to equipment limitsKnow the protection layers (safeguards) and ways that they can be compromisedUnderstand administrative/

7、procedural layers of protection and how you can measure their effectivenessCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersProcess Safety Competency (1)Be able to continuously improve the risk profile in your area of responsibility by applying lessons

8、 from Local production unit (your unit)Other production units in your companyIncidents at other companies within your industryIncidents in industries different than your ownCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersRate the following groups in y

9、our plant against the items in the “Process Safety Competency listThe process operatorsThe shift team leaders/supervisorsThe Unit leaderThe members of the Site Manager staff Discussion QuestionsCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersTraining

10、for EngineersTraining for Operations ManagementShift team leadersUnit LeaderOperations ManagerSite Manager Process Safety TrainingCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersTraining for EngineersFor each of the Critical PSM elements in the Organi

11、zation/Management Template for the Design/Engineering column, do the following:Create a table as shown below, and fill it inExerciseCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersElementTrain only a fewSome training for allCreate an on-site expertUse

12、 outside expert onlyEngineering & Equipment StandardsTeams give the best decisions Correct?What are ways to provide engineers the PS competencies that they need?DiscussionCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersTraining for Operations Manageme

13、ntAsk the following question for each operations management level, and for each of the process safety competency items:“Does this management level need to have this competency in order to make good decisions in his/her role?Fill in the table on following page, using “N for “need to know, and using “

14、D for “do not need to knowExerciseCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersTable for the ExerciseCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersCompetencyShift Team LeadersUnit LeaderOperations

15、ManagerSite ManagerKnow the hazards of the processKnow where the process can pose a threat to equipment limitsKnow the protection layers (safeguards) and ways that they can be compromisedUnderstand administrative and/or procedural layers of protection and how you can measure their effectivenessIn yo

16、ur organization,Do you test your managers to make sure they have the Process Safety competency knowledge they need to make the decisions they are required to make? If yes, describe.When a new person transfers into an operations leadership role, what is the mechanism for them to acquire the PS compet

17、ency knowledge that they must have before they start making key decisions?Discussion QuestionsCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engineers16Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersManagement

18、Select and Hire Right People for the RoleExerciseList the criteria used at your workplace to Hire operatorsHire engineersAppoint operations unit leadersSelect/Hire Right PeopleCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersMany criteria to think abou

19、t, but two that we should highlightCapable of grasping technologyImportant in the operator ranksEqually important management position selectionsAvoid rotation of individuals into manufacturing jobs “to get them experience if they cannot grasp the technology“Enforcement of rules is situational Screen

20、 these types out of the group aiming at leadership roles. They can destroy a good process safety culture overnightSelect/Hire Right PeopleCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engineers19Copyright 2021 Center for Chemical Process Safety of the Americ

21、an Institute of Chemical EngineersManagementCulture and Employee EngagementProcess Safety CultureWhat Is It?The combination of group values and behaviors that determine the manner in which process safety is managedHow we do things around hereWhat we expect hereHow we behave when no one is watching20

22、Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhy Is It Important?Investigations of catastrophic events have identified common process safety culture weaknesses that are often factors in other serious incidentExamples:Lack of enforcement of high saf

23、ety standardsNo sense of vulnerabilityPoor communicationsDelayed or no response to process safety issues and concerns21Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersChallenger - 198622Copyright 2021 Center for Chemical Process Safety of the American

24、 Institute of Chemical EngineersSolid Rocket (Cutaway)23Solid Rocket Motor propellant and aft field jointCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersImmediate (Technical) CauseFailure due to faulty design, unacceptably sensitive to:Effects of temp

25、eraturePhysical dimensionsCharacter of materialsEffects of reusabilityProcessingReaction of the joint to dynamic loading24Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersCulture Related FindingsReporting requirements for issues/problems not concise. U

26、nable to get critical information to the proper levels of management in proper time frame.Little or no trend analysisIneffective organizational structuresWork force decrease in reliability and quality assuranceFlawed launch decision making process25Copyright 2021 Center for Chemical Process Safety o

27、f the American Institute of Chemical EngineersRecommendationsReview of Shuttle Management StructureRedefinition of the Program Managers responsibilityEstablish Shuttle Safety PanelRepresentation from the safety organization, mission operations, and the astronaut officeAddress shuttle operational iss

28、ues, launch commit criteria, flight rules, flight readiness and risk management 26Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersRecommendationsCriticality Review and Hazard AnalysisEstablish Safety OrganizationOffice of Safety, Reliability and Quali

29、ty Assurance to be headed by an Associate administrator, reporting directly to the NASA AdministratorEnsure adequate oversight of functions 27Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersChemical and Refining IndustriesSymptoms of Weak Culture (1)L

30、ack of awareness of operational safety risks by senior managementPoor housekeeping prevalent leaks, spills and debrisLack of engagement/involvement by management in daily oversight of PSM systems.Superficial audits “check the box mentalityCopyright 2021 Center for Chemical Process Safety of the Amer

31、ican Institute of Chemical EngineersChemical and Refining IndustriesSymptoms of Weak Culture (2)Chronic cost cutting and production pressures in absence of an increased focus on critical PS hazardsInadequate metrics misplaced confidence in injury ratesLack of follow-up on process safety concerns hug

32、e backlog of action itemsPoor incident reporting, learning and risk reviewCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersCauses of WeakProcess Safety CultureLack of process safety leadership (priorities, involvement)Low-discipline operating environme

33、ntNormalization of deviance reliance on luck and false sense of securityNon-responsiveness to safety concernsFailure to learn and adjust the status quoLack of effective performance monitoringLack of trust (subordinates and supervisors)Not listening to technical experts 30Copyright 2021 Center for Ch

34、emical Process Safety of the American Institute of Chemical EngineersHow To Build a Process Safety CultureEstablish Process Safety as a core valueProvide strong leadership at all levelsEstablish and enforce high standards of performanceInsure that all leaders are fully aware of process risks and the

35、 safeguard layers in their area of controlEmpower individuals to successfully fulfill their safety responsibilitiesDefer complex problems to qualified technical expertsEnsure open and effective communications foster mutual trustProvide timely response to Process Safety issues and concerns31Copyright

36、 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersQuestionsWhat aspects of your companys process safety culture are good (Top 3) and which could use improvement (Bottom 3) based on your judgment?What 2 cultural weaknesses could you fix quickly in your area after

37、 you return from this course?What 2 cultural weaknesses, if addressed company-wide where you work, would bring the greatest reduction of risk in the plant?32Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersThe specific activities that insure:That opera

38、tors/mechanics are engaged in process safety reviews and incident investigationsThat operators/mechanics have knowledge of recommendations from safety reviews, audits, and incident investigations, and are kept aware of the status of those recommendations33What Is Workforce Involvement?Copyright 2021

39、 Center for Chemical Process Safety of the American Institute of Chemical EngineersEngaging the operators and mechanics provides feedback and insight into the process that is only available from those who operate and maintain the equipment every day.Example: The highest risks in a process are almost

40、 always at non-steady state conditions. In a PHA, engineers are excellent sources of insight on steady-state behavior of the unit, but operators are the best sources of insight for non-steady state or abnormal operations.)34Why Is It Important?Copyright 2021 Center for Chemical Process Safety of the

41、 American Institute of Chemical EngineersDescribe/give examples based upon where you work:Operator/mechanic involvement in critical PS incident investigationsFeedback and information sharing systems which insure that operators/mechanics are aware of status of all key Process Safety recommendations (

42、PHAs, incident investigations, etc)35Workforce InvolvementQuestions for discussionCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhy are we only focusing on engagement of operators and mechanics?What did we learn from application of Total Quality Man

43、agement to manufacturing operations?Exercise: Name 3 steps that could be taken to increase employee engagement, and tell how each would create better performance in PSM36Moving from Workforce Involvement to Employee EngagementCopyright 2021 Center for Chemical Process Safety of the American Institut

44、e of Chemical Engineers37Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersManagementMeasurement and MetricsWhy It Is Important?Facilities should monitor the real-time performance managements systems rather than wait for incidents or for infrequent audi

45、ts to identify management system failuresPerformance monitoring allows problems to be identified and corrective actions taken before a serious incident occurs38Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhy It Is Important?39Copyright 2021 Center

46、 for Chemical Process Safety of the American Institute of Chemical EngineersYou Cannot Manage What You Cannot MeasureYou Will Not Manage What You Do Not Choose to MeasureMeasurement and MetricsEstablish performance and efficiency indicators to monitor the near-time effectiveness of your PSM program.

47、Need to consider:Which indicators to use (leading, lagging, or mixture)How often to collect dataHow utilize the data40Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersProcess Safety Leading Indicators - ExamplesNumber of open recommendations from PHAs,

48、 Incident Investigations, Audits, etc.Number of near miss incidents submittedNumber (or percent) of overdue PM tasks on safety critical systemsCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersProcess Safety Lagging Indicators - ExamplesNumber of fires

49、and explosionsNumber of Loss of Containment events without fire or explosionNumber of injuries that tied to loss of containmentCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersLeading or LaggingThe Debate is EndlessThe shortcoming of Lagging Indicators

50、 is . ?The shortcoming of Leading Indicators is . ?So use a mix and problem solved?Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersSelecting Metrics What Does the Accident Pyramid Teach Us?Copyright 2021 Center for Chemical Process Safety of the Ameri

51、can Institute of Chemical EngineersThere is actionable information at the base of the pyramid to give us feedback on what is working and what is not.Uncontrolled Release of Chemical or EnergyProtective BarriersHoles or WeaknessesSelecting Metrics What Did the Barrier Model Teach Us?45Process Deviati

52、onFrom EventCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersMars Climate Orbiter - 199946Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersDiscussion ExerciseUsing the Behavior Leading Indicator model, de

53、velop 10 PSM metrics that would be of value.Using the Accident Pyramid model, develop 10 PSM metrics that would be of value.Using the Barrier Model, develop 10 PSM metrics that would be of value.47Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engineers48Copy

54、right 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersManagementAuditingAuditingA systematic, independent review to verify conformance with prescribed standards of careEmploys a well-defined review process to ensure consistency and to allow the auditor to reach

55、 defensible conclusionsAn RBPS management system audit is the systematic review of RBPS management systems to verify suitability and effective, consistent implementation49Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhy Is It Important?Evaluates RB

56、PS management systems to ensure they are in place and functioning in a manner that protects employees, customers, communities, and physical assets against process safety riskAre an important control mechanism within the overall management of process safety50Copyright 2021 Center for Chemical Process

57、 Safety of the American Institute of Chemical EngineersLongford51Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersAuditing IssuesAuditing by Exxon in 1994, 1997 and 6 months prior to incident following OIMS (Operational Integrity Management Systems) go

58、od report card/ findings related to improving the systems/“risk assessment and management slipped from 4 to 3Victorian Workcover audit in 1996 good report - mapped H&S management systemsESSO internal review 4 months prior - positive resultsCopyright 2021 Center for Chemical Process Safety of the Ame

59、rican Institute of Chemical Engineers Compliance AuditsConduct audit At least every 3 yearsCertify evaluation of complianceVerify procedures and practices are adequate and being followedBy self, by company representatives, by a consultant Audit teamAt least one person knowledgeable in the process 53

60、Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engineers Compliance AuditsReport of findingsDetermine appropriate response to each findingCorrect deficienciesDocument actionsTrack to completionRetain two most recent audit reports54Copyright 2021 Center for Ch