What are the most common gaps in process safety audits and how can you address them?

In my opinion, there are a further 2 critical elements to the successful implementation of process safety audits. These are:- 1. Clear and unequivocal support from senior management, with evidence that previous audit findings have been swiftly and effectively acted upon. 2. A culture that supports open and honest communication in the audit. All those partaking in the audit need to be confident that they can share experience and knowledge without fear of reprisals.

Incomplete Documentation: Missing or incomplete documentation related to safety procedures, equipment specifications, and emergency response. Inadequate Training: Insufficient training for personnel involved in operating and maintaining equipment. Failure to Learn: Lack of a robust incident investigation and reporting system. Failure to Address Human Factors: Overlooking the impact of human factors on safety, including fatigue, complacency, and inadequate communication. Inconsistent Compliance Monitoring: Inconsistencies in monitoring and ensuring compliance with safety regulations and standards. Failure to Involve Frontline Workers: Lack of involvement of frontline workers in safety decision-making and hazard identification.

Inadequate Risk Assessment: Gap: Failure to conduct a thorough risk assessment may lead to unidentified hazards. Addressing: Implement a comprehensive risk assessment process, including hazard identification, risk analysis, and prioritization. Regularly update assessments to account for changes in processes or technology. Lack of Employee Involvement: Gap: Employees may not be actively engaged in the audit process, leading to overlooked safety concerns. Addressing: Foster a culture of active employee involvement. Encourage open communication, provide training on hazard recognition, and involve workers in safety audits. Their insights can be invaluable in identifying potential risks.

In my opinion, process safety audits can be improved by concentrating on assessing the practical performance of safety systems rather than just compliance, making sure audits occur on a regular basis for ongoing oversight, incorporating gap analyses to find weaknesses, using data analytics to make well-informed decisions, and making sure the audit team is knowledgeable about safety standards and procedures.

Escopo inadequado é resultado de profissionais não preparados. As auditorias não começam quando os auditores chegam na área ou empresa que será auditada. No momento do planejamento se não houver conhecimento profundo do processo que será auditado e principalmente conhecimento técnico de modelos de auditoras, análises de processos e seus: - Gap´s - Riscos - Regulação Vigente - Como tem que ser feito o processo, para analisar se há ou houve erro durante o período auditado. Auditoria de processos não pode ser feita no estilo "Ctrl Copy", é única e cada processo deve ter seu escopo bem desenvolvido, itens de regulação conhecidos e evidências documentadas da capacitação dos profissionais envolvidos.

El punto álgido a considerar es la formación, capacidad y experticia de cada uno de los miembros del equipo que efectúa la auditoría. Si el equipo cumple con este requisito se consideran los tiempos y herramientas necesarias.

Process safety audits are crucial for identifying and addressing potential hazards in industrial processes. Common gaps in process safety audits may include: 1. Inadequate Risk Assessment: 2. Lack of Documentation: 3. Insufficient Training: 4. Ineffective Management of Change (MOC) Process: 5. Inadequate Process Controls: 6. Poor Emergency Response Planning: 7. Failure to Learn from Incidents: 8.Inadequate Mechanical Integrity: 9. Poor Communication and Culture: 10. Incomplete Process Safety Information

Also, if you know a safety audit is coming up, don’t do extra things to make your area extra clean and safe looking. Let the audit catch some things that may be a concern, but not generally done during shift housekeeping. Walk with the auditor and discuss any hazards you know of that they didn’t find or missed. Set your standards above the companies standards. So your worst piece is still well within spec. That will cut down on scrap and rework. Spend the time every day on housekeeping even if you are the only one doing it. Eliminating trip hazards can save yourself from injury, but other people coming into your area as well.

Na minha área de atuação, o órgão regulador orienta que pelo menos uma auditoria anual as organizações devem apresentar. Nos clientes que presto serviços, sempre orientamos que pelo menos 03 auditorias devem ser feitas anualmente, sempre que: - Houver mudança significativa de normas e guidelines e que serão críticos aos processos; - Quando a área de pesquisa e desenvolvimento lançar um novo produto ou mudar características do produto que já está no mercado e - Ao receber reclamações de clientes, sobre EA - Efeitos Adversos, graves e críticos. A periodicidade da auditoria deve ser definida pela Alta Direção, com a participação de toda área técnica, haja vista que são esses profissionais que possuem o conhecimento profundo da regulação.

inadequate documentation, insufficient training, poor management of change procedures, lack of risk assessment updates, and ineffective emergency response planning. Regularly reviewing and addressing these gaps is essential for maintaining a safe working environment

Field visit can tell a lot about the process safety culture in an organization. One can have fancy procedures and checklists etc but on ground implementation will tell the real story.

Se fizermos uma interface entre Gerenciamento de Projetos e Auditorias, perceberemos que a utilização da metodologia são muito parecidas e quando bem utilizada, servirá como ferramenta para desenvolvimento de resultados, que são: Integração, Escopo, Tempo, Custos, Qualidade, Aquisições, Recursos, Comunicação, Gerenciamento de Riscos e Gerenciamento das Partes interessadas. Uso bastante o PMBOK nas auditorias e como ferramenta métrica de riscos, o FMEA.

Se pensarmos nas ferramentas disponíveis para comunicação e compararmos com as de 20 anos, certamente poderíamos afirmar que não deveríamos ter problema de comunicação. Sem dúvidas, é necessária a comunicação clara, objetiva e robusta do que a auditoria busca evidenciar, onde podemos como auditor colaborar na solução de ausência de conformidade e sempre ter aptidão para ouvir o auditado. Momentos de auditoria deixam profissionais agitados, ansiosos e muitos nervosos ao extremo. Quando entro em uma auditoria, na reunião de abertura eu sempre digo: "Estou aqui com a régua e o lápis, o primeiro objeto colabora no equilíbrio do que estiver não conforme e o segundo aponta o que e como podemos melhorar os processos. Nunca martelo e serrote!"

Quando cheguei a conclusão da montagem da ConceitoQ Consultoria e Projetos, tive a preocupação de reunir as melhores organizações e entregar aos clientes não só um relatório de auditoria com ações para ele cumprir. Nós auditamos e nossa estratégia é levar quando necessário essas empresas de software, de desenvolvimento em normas ISO, equipamentos para monitoramento de medicamentos e etc. Nós só fechamos a consultoria/auditoria quando os clientes passam pela inspeção sanitária com a emissão do certificado de Boas Práticas. E durante 12 meses subsequentes, mensalmente avaliamos a aplicabilidade das melhorias nos processos de cada empresa.

In addition to the mentioned considerations for process safety audits, investing in qualified auditors with industry expertise is crucial. Leveraging technology, such as data analytics and AI tools, enhances risk assessments and improves audit efficiency. Embracing a continuous improvement culture encourages reporting of near misses and ongoing safety learning. Closing gaps requires a holistic approach, integrating risk-based methodologies, effective communication, and a commitment to continuous improvement. This comprehensive strategy ensures impactful process safety audits, reinforcing an overall plant safety culture that prioritizes ongoing enhancement and comprehensive risk management.

In my opinion, Common gaps in process safety audits include insufficient hazard identification, poor documentation, and lax safety procedure compliance. Address these gaps by conducting thorough hazard analyses like HAZOP, improving documentation practices, and implementing regular training programs. Foster a proactive safety culture by encouraging open communication and reporting. Regularly update safety procedures based on industry standards and conduct comprehensive audits to rectify any identified gaps in the safety management system.

Lack of Management support. Open Management have some sort lack of full support to Safety audit due to budget constrain. They still have the so called production first mentality. This kind of poor understanding In the Safety should be avoided. Management must Focus on the importance of keeping All employees Safe because the Management Will harvest their investment to Safety By having NO accident or incident In their business Will Show How the culture of Safety In their business.

Gap 1: Inadequate audit scope. Gap 2: Insufficient audit frequency. Gap 3: Ineffective audit methodology. Gap 4: Poor audit communication. Gap 5: Lack of audit follow-up.

Unclear and impractical recommendations that aim to achieve unrealistic gold standards, that add complexity and further bureaucracy to a process that is already broken.