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Lelwyn D’Souza

VP Supply Chain AP

8th September 2017

“Our Process Safety Metrics

and the Learning Journey”

02/10/2018

CCPS Asia Pacific Regional TSC Meeting,

Singapore

Bala Raman

Process Safety Manager, Ecolab - Asia Pacific

Presentation Overview

ECOLAB- Our Purpose and values,,

Where we see Risks ?

What causes these Risks?

Managing down the Risks….

Sustaining the gain!

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SAFETY EVERYWHERE.

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Global Company, Global Reach

Founded in

1923Headquartered in

St. Paul, MN

FORTUNE

500COMPANY

48,000+Total employees

1 millionCustomer Locations

Serving customers in

171 countries

115 $13 billionin annual sales

Total manufacturingfacilities

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We are Set Up to Support and Supply our Customers Globally

19 technology centers

115 plants 48,000

employees

171

countries

25,200

sales-and-service representatives

more than220 warehouses

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115

220

171

48000

25200

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Ecolab: Providing + Protecting What’s Vital

Clean Water Safe FoodAbundant

Energy

Healthy

Environments

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We Develop the Best Business Solutions by Solving Real-world Problems

8 Regional Technical Centers

1,600 Scientists 6,700 Patents

11 Global Research Centers

• Bangkok

• Campinas

• Dusseldorf

• Eagan

• Greensboro

• Naperville

• Pune

• Shanghai

• Singapore

• Sugar Land

• Sydney

• Tokyo

• Monheim

ECEcolabNalco

Champion

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Every Year, Ecolab Helps:

Meet 45%of the global demand

for petroleum products

604 BILLION

Fuel

cars

of the world’s processed food

45 BILLION

Serve

meals

Produce

MORE THAN A QUARTER

42%Produce

of the global processed

milk supply

694 BILLION

pounds a year=

nuclear power

of all

Generate

22% 40%of the world’spower

1 BILLION+Clean

hotel rooms

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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

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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 CAMPAIGN10

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”

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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

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Data Analysis and Improvement PlanAsia pacific

Performance Profile (Loss Tree) 2019 Focus Area

Level 1

Level 2

Level 3

• Leadership engagement and Knowledge

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 .

MI : 57%

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TPM (TOTAL PRODUCTIVE MAINTENANCE) IS PART OF LIFE

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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

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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

Setting focus / priority

Hazard Recognition

Flammables

Unplanned Mixing /Incompatibility

Open Ends

Metrics

SMS

HIRA16

Any Critical

Needs?

Flammables

Chemical Incompatibility

Open Ends

Critical Equipment Root Causes

80:20 – Hit the Big Ones

Leverage Learning

Taproot5 Whys

Where’s the

risk?

What’s the

Priority?

Public

Data

Evaluating Risk, Identifying Causes-Global

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Example – “Red List” & Reactivity Outcomes Table

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

Red List / Reactivity Matrix

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PSE Metrics in Logistics Area- New

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Critical Equipment Program via PM Pillar –Committed Effort

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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

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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

Ecolab Risk Profile Tool

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Sustain: Reward& Recognition

“Spot the Risk”

Poster contest

Leading

metrics

Award

1 Year

Zero TRIR,

Tier 1 PSE

Award

5 Year

Zero

Award

“Open Ends” contest

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• Reward & recognition

• Training

• Roles & Responsibilities

• Standards

• Practices

• Specifications

• “Blue Books”

• Critical Equipment (SHE Elements)

• MI program

• Plant Manager Qualifications

• SHE Program

• Procedures

Operations Maintenance

Human

ResourcesEngineering

Leverage

Sustain: Integrating into Culture

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Sustain: Training Framework

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Example: Plant Managers Qualification

Sustain: Accountability

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Ecolab Standards Development Flow

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What’s Working well so far,

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

50%

Redux

After 2

years

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QUESTIONS? &

THANK YOU.