Operational Excellence Round Table—Driving Continuous Improvement in R&D, Pilot Line and Manufacturing Organizations Using Risk Based Approaches

Andy McIntyre; Steve Trammell
(BSI EHS Services and Solutions, San Jose, CA)

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Co-Moderated by: Andy McIntyre, CIH – BSI EHS Services and Solutions Steve Trammell, PE, CSP, CCPSC, CHMM – BSI EHS Services and Solutions Panelists: Jerry L. Jones, PE, CSP, CHMM – Chemical Engineering Consultant Industry leaders / subject matter experts – in progress Operational Excellence (OE)is all about driving continuous improvement and requires a sound strategy and HARD work. It should not be defined only in terms of tactics such as business process improvement tools or techniques (Six Sigma, Lean Mfg., 5S, etc.). OE is a journey and is better described as an organizational mindset or culture dedicated to the pursuit of continual improvement in performance across all functions. While those in manufacturing organizations agree that OE initiatives can help improve product quality/delivery and the safety, reliability and profitability of operations, a key challenge is to set priorities and allocate resources among many target areas with opportunities for improvement, which includes: raw materials supply chain/product distribution optimization, site acquisition risks, equipment design for safety, reliability, maintainability, environment and sustainability during the procurement, equipment installation review and certification, mfg. process control technologies to improve mfg yields/productivity/quality, evaluating and managing change, equipment maintenance and reliability (onstream issues & releases), changing workforce demographics & competency, protection of intellectual property & cybersecurity, occupational safety and health, process safety, environmental protection & sustainability throughout the facility lifecycle, planning/preparing for abnormal or emergency situation. In this roundtable discussion the panel members will address how: numerous management system consensus standards and guidelines can help an organization answer if they are “doing the right things” in specific topic areas; integrating management systems is important to efficiently utilize resources and cost effectively drive improvement; self-assessments and benchmarking help answer the question of “how well they are executing” those tasks & business processes; risk based decision making and risk reduction effectiveness throughout the EHS&S continuum are logical approaches for setting organizational priorities, deciding when to go beyond minimum standards, and allocating resources. The focus of the discussion by the panel members in this 1.5 hour interactive roundtable, will be risk management systems based on AIChE CCPS Risk Based Safety Guidelines and other relevant standards,( e.g. ISO 31000: 2018, ISO 45001: 2018, ISO14001: 2015) and how effective integration is a foundation for driving continuous improvement in an organization and throughout the facility lifecycle.

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