What do you do if your plant operations need a safety boost from new technology?

I would go for Pilot Testing: Evaluate new technology's efficacy under practical circumstances by conducting pilot testing prior to complete integration. This aids in comprehending the functionality of the technology and how it affects operations.

If the decision is taken that the safety boost is needed, obviously that is based on the outcome of a risk assessment which guides you to decide what safety upgrade you should do to reduce to inherent risk. But surely this upgrade should follow by another risk assessment which defines the new risk profile (actual) post upgrade.

As being part of operation leaders, assessing risks before embracing new technology is crucial. Identifying hazards, gauging incident probabilities, and anticipating outcomes' severity are key. This process sheds light on safety gaps and guides targeted tech investments. It's more than acquiring trendy tools; it's about wisely leveraging tech to tackle precise safety challenges.

It can be very easy to fall into the "trap" of driving straight toward some sort of technological tool or "solution" without understanding the broader picture: why did the risk arise in the first place? What is the workplace culture in terms of safety? Do front-line leaders have the support - and accountability - to actually drive proactive safety? Has senior management made workplace safety a clear company value, or it is given "second place" when other matters arise?

To boost a safety with technology a)I recommend to use face/finger authentication at entrance. b)Fall from height is a high risk activity to reduce the same I recommend sensors on safety harness and helmets to monitor the workers are wearing while working at height. c) Digital permit system and approval of the same by using android mobile phones. d)Virtual training to all staff and workers to make them understand about the hazard and risk in their routine activities. e) All equipment, Machineries and power tool inspection by using digital scan system and same can cross check by all concern staff by scanning the QR code. f) Installation of alarm sensors confined space, shafts, edges to trigger the workers once they enter high risk area.

After upgrades on a new plant, new case scenario introduces a new risk. How to minimize these risk has to take a form of process Operational safety control.

Incorporating new technology is ineffective without thorough staff training. Empowering employees with comprehensive programs ensures proficiency in utilizing these systems for enhanced safety. By equipping them with the necessary tools and knowledge, we empower our workforce to uphold a secure work environment. Continuous training and support amplify the advantages of our technological investments.

Integrate real-time data analytics to enhance safety monitoring in your plant operations. Set up advanced dashboards that provide instant feedback on safety metrics like incident rates and compliance levels. This proactive approach allows for immediate adjustments, ensuring that new safety technologies not only meet but exceed expectations, keeping your operations at the cutting edge of industry standards.

As a HSE manager, incorporating new technology prompts a thorough review of safety policies. It's vital to align current policies with the capabilities of the new systems, ensuring compliance and fostering a safety-driven culture. Clear and updated policies empower us to harness technology effectively, enhancing the safety of our plant environment and supporting regulatory adherence.

In my experience new equipment integration into the production process requires a concurrent engineering team. This team is lead by a PE or project manager. The team members should be line / facility maintenance, area supervisor, two highly tendered employees, a QC technician, warehouse employee / lead and tool & die. Once the design has been identified this group will review and evaluate the implementation of this project on their respective areas of expertise. Equipment layout, safety, maintenance servicing, staging / movement of materials, employee machine interface…. This process gives the internal customer a voice in determining the success of the project. This team buys into the process and takes ownership of the outcome