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How can you design processes that prioritize efficiency and safety?

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Efficiency and safety are two essential goals for any workplace, especially in industries that involve hazardous materials, complex machinery, or high-risk environments. However, achieving both objectives can be challenging, as they may require different strategies, resources, and trade-offs. How can you design processes that prioritize efficiency and safety without compromising either one? Here are some tips to help you create a balanced and effective process safety engineering and design.

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1 Assess the risks

Before you start designing or modifying any process, you need to identify and evaluate the potential hazards and risks that it may pose to your workers, equipment, and environment. This can be done by using various methods, such as hazard identification (HAZID), hazard and operability study (HAZOP), failure mode and effects analysis (FMEA), or fault tree analysis (FTA). These methods can help you determine the likelihood and severity of different scenarios, as well as the possible causes and consequences of failures.

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Ben Horstmann

Director at Consolidated Plant Services
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The mistake most people make when assessing process risk is only assessing face value safety risk; rarely is organisational, reputational or cultural impact risk considered. Invite genuine consultation from people at the coal face of the process and make significant effort to understand their perspectives. Should you consider these aspects of the process there will naturally be a significant safety/ efficiency improvement, consider the cultural risk of excessive manual handling for a task with little change (eg the same action many times with little variation). Not only is excessive manual handling a significant safety risk but also hinders moral, by making peoples lives easier you can significantly strengthen your work force.

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2 Implement the controls

Once you have identified the risks, you need to implement the appropriate controls to prevent or mitigate them. Controls can be classified into three types: engineering, administrative, and personal. Engineering controls are the most effective, as they involve designing or modifying the process or equipment to eliminate or reduce the hazards. Examples of engineering controls are alarms, sensors, valves, interlocks, or barriers. Administrative controls are the second most effective, as they involve establishing policies, procedures, rules, or training to guide the behavior of workers and ensure compliance with safety standards. Examples of administrative controls are checklists, manuals, audits, or inspections. Personal controls are the least effective, as they depend on the individual actions of workers to protect themselves from the hazards. Examples of personal controls are personal protective equipment (PPE), such as gloves, goggles, or masks.

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Ben Horstmann

Director at Consolidated Plant Services
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When implementing controls, understand its rare they are as effective as proposed. The review stage needs to start at point in implementation but more importantly be aware of unplanned introduced risks that have occurred as a result of the change and is the collective reduction less than the risk prior to the change?

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3 Monitor the performance

After you have implemented the controls, you need to monitor the performance of the process and the effectiveness of the controls. This can be done by using various indicators, such as key performance indicators (KPIs), leading and lagging indicators, or near misses. These indicators can help you measure and track the results of your process safety engineering and design, as well as identify any gaps, weaknesses, or opportunities for improvement. You should also collect and analyze feedback from your workers, customers, or stakeholders to understand their perceptions, expectations, and satisfaction with the process.

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Maria Johnson, MBA

Vice President of Development / Vice President of Facilites and Construction / Board Member / Brand Growth & Expansion / Executive Leadership for Restaurant or Retail Industry
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Monitoring performance is like having a safety GPS for your processes. Key Performance Indicators (KPIs) are the signposts telling you if you're on the right track. But, here's a twist: don't just rely on the numbers; gather insights from the real heroes—your workers, customers, and stakeholders. Their feedback is the secret sauce for fine-tuning your safety and efficiency recipe. Let's not forget: every beep on the safety radar is a chance for improvement!

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Ben Horstmann

Director at Consolidated Plant Services
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Be real about the performance, monitor only what matters. Use previous indicators only as a starting point to determine the actual key indicators in the current scenario. Consult with coal face workers to see if the indicators chosen are true to the environment this is actually happening and can the numbers be warped at a ground level giving false outcomes.

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Marcus van Enk

2024 construction tools for the modern construction manager | driven by 4 core pillars ?? sustainability ?? eco systems (business and environmental) ?? business to enable the above? ?? tech to enable business
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Capturing those lead indicators is the real challenge in this, making it simple and efficient. Most data capture systems on the market today make it a real effort for field workers to record the critical data that will produce real lead indicators. We have found such a varied mix of data capture methods in a single organisation can result in data manipulation as the data makes its way to the people that need it. Conclusion; Make it a point to prioritise simple to use tech for field operations that enable accurate data capture on structured format that can then be used to report accuracy to all the stakeholders that require it and that can make positive change.

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4 Review and improve

Finally, you need to review and improve your process safety engineering and design regularly and systematically. This can be done by using various tools, such as audits, inspections, reviews, or investigations. These tools can help you evaluate the compliance, effectiveness, and efficiency of your process and controls, as well as identify any root causes, corrective actions, or preventive actions for any incidents, accidents, or near misses. You should also benchmark your process against best practices, standards, or regulations, and implement any changes or innovations that can enhance your process safety engineering and design.

By following these tips, you can design processes that prioritize efficiency and safety, and achieve both objectives without compromising either one. You can also create a culture of continuous improvement and learning, where you and your workers are always striving to optimize your process safety engineering and design.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you design processes that prioritize efficiency and safety?

1

2

3

4

5

1 Assess the risks

2 Implement the controls

3 Monitor the performance

4 Review and improve

5 Here’s what else to consider

Workplace Safety

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How can you design processes that prioritize efficiency and safety?

1

2

3

4

5

1 Assess the risks

2 Implement the controls

3 Monitor the performance

4 Review and improve

5 Here’s what else to consider

Workplace Safety

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