More planned work and more time for safety

DSM SINOCHEM Pharmaceuticals Production Delft is engaged in the production of intermediates for fighting bacterial and fungal infections, the production of enzymes and the treatment of wastewater. The site is the market leader in the production of 7-ADCA. The 7-ADCA plant operates with a 5-shift system without team leader (autonomous teams). Their operators continuously improve in both safety and efficiency in production.

200

work permits per week

70

people involved in the process

Customer Case

DSM SINOCHEM Pharmaceuticals Production Delft works with work permits based on the Deltalinqs systematics (commonly used in the Rotterdam Harbor area). The procedure was good, but the administrative hassle of the paper system required a lot of time of the parties involved. For recurrent work, all actions had to be repeated every time. Furthermore, it was difficult to obtain an overview of the status of the various work activities. Manual entry resulted in inconsistent following of procedure and the poor legibility could lead to misunderstandings. People were complaining about the time-consuming procedure resulting in the focus not always being on the goal you were striving for, notably working safely and safety.

DSM SINOCHEM Pharmaceuticals Production Delft needed a solution that could contribute to increased safety and that would make the Permt to Work process more efficient.

Situation

DSM SINOCHEM Pharmaceuticals Production Delft issues approximately 200 work permits per week. 70 people from production and maintenance are involved in this process. The Deltalinqs form was first entered in Excel by maintenance and then by the shifts; High-Risk permits were not explicitly identified. The permits were issued on paper to the maintenance staff in the morning, who then returned the permit at the end of the day.

Actions

DSM SINOCHEM Pharmaceuticals Production Delft decided not to develop something by itself. With Unite Permit to Work iB&X was able to provide the combination of focus on the human being, the work process as a foundation, and a support system. The solution offers sufficient flexibility to maintain the existing work method (in this case Deltalinqs) as a basis and, at the same time, to implement solid improvements based on the best practice.

As DSM SINOCHEM Pharmaceuticals Production Delft wanted to evaluate whether Unite Permit to Work matched the requirements, the ZOR-f unit was selected for a pilot installation in one of the plants. First, a representative group of maintenance, production, and HSE was formed, followed by an inventory of the problems and goals of the project, and where necessary succeeded by modifications of the procedure. This created a renewed attention of all parties involved to safety and foundation, and constituted the basis for the configuration of the system. Employees of iB&X and DSM SINOCHEM Pharmaceuticals Production Delft subsequently ensured that all 45 users were trained and motivated in less than four weeks to increase the efficiency and safety by means of the modified work method and the new system. After a positive evaluation, Uniter Permit to Work was not only implemented at the ZOR-f unit, but also at the other production units.

Results

In 2007, DSM SINOCHEM Pharmaceuticals Delft participated in the expansion of Unite Permit to Work with conditional permits in order to prevent adverse interactions between work(permits). A permit for opening the installation, for example, may not be issued if a permit for grinding is still active, another example is a permit for the removal of isolation/locks that can not be issued as long as any permits for maintenance are active. This module was introduced in mid 2007.

The project, the introduction of PermitCliq and the extension with conditional permits have lead to the following results:

  • There is a clear, transparent procedure. Incidents and problems due to illegibility, incorrect filling in, interaction risks or circumventing the procedure are now quite rare.
  • There is a more efficient preparation for safe working; for repetitive maintenance activities "standard" work permits are used as a basis and for planned work the permits are issued in a quick and systematic manner. In plannable work we have seen tremendous progress. Previously, the application of a technical planned action started slowly, while now, after the planning meeting all permits have already been created.
  • The double entry of data is reduced to a minimum,
  • Continuous and complete overview of the activities to be planned, active works, finished permits and permits to be renewed.
  • During large projects there is a good insight in what is about to happen and what the issuer needs to do.
  • People have more time for what's really important: safety.

‘“The number of incidents, wrongly used and/or incomplete work permits has been reduced to a minimum.’

Progress

Meanwhile, Live Saving Rules (LSR) were introduced, raising the bar even more. DSM SINOCHEM Pharmaceuticals Delft has integrated these rules in the Permit to Work process.

User experiences

Daniel Verloop, Operation Expert ZOR-f:

“The number of incidents, wrongly used and/or incomplete work permits has been reduced to a minimum, compared to when paper work permits were used. Responsibility, in combination with safety during preparation, execution, and acceptance, has increased to the desired level.

The work permit, as an umbrella for setting agreements concerning the performance of the task, and in which the various disciplines record their responsibilities, dos and don’ts, is back at the level that is an absolute must for a production department.

The various projects we have realized in recent years with iB&X in order to increase the safety and efficiency here in Delft have become a success in a pleasant and professional cooperation.”