psm project gb presentation zxm

This presentation is for planning and study purposes only. Proposals and options contained herein are subject to review, approval and any legallyrequired notice, collective bargaining and consultation obligations.

Improve Identification ofPSM Covered Processes

GBPL: XiaoMing ZengCorp. HSE, APAC

2014

Status: Certified

2Preliminary – not final – no decision will be taken without satisfaction of any applicable consultation or negotiation requirements.


Project CharterElement Project Information

0. Project Title Improve Identification of PSM Covered Processes

1. Area of Focusor Function:

PSM, Corp. HSE;Scope: Geographically APAC One-HON sites where with ASM supports; Operating modes of existing assets andacquired assets including JVs where HON has operational control; Business scope includes all SBGs (including TSfor confirmation);

2. ProblemStatement

Some SBG do not recognize PSM covered processes on their facilities, esp. those outside of PMTmanufacturing sites. Thus Process Safety is not managed in a consistent and effective way on those sitesmissing the identification. Examples include the Tier 1 PS incident Event ID: 398014 with root causesidentified as not PSM covered process.

3. Benefit toCustomers:

The customers of this project include those SBG leaders, SBG site leaders, Site HSE leaders and the impactedpersonnel with PSM covered processes. By using a screening tool to determine the covered processes,adequate PSM support and resources can be allocated to those covered processes and PSM performance canbe improved. Adequate PSM system if identified for the covered processes will reduce the likelihood and losesof PS events.

4. ProjectMetrics: Metrics: Baseline Goal Entitlement Units

Rate(Successful Id of PSM applicability)

Not currentlymeasured

90% Goal %

Coverage(Screening sites in the region)

Not currentlymeasured

100% Goal %

5. BusinessImpact

Improve PSM performance on non-PMT sites and reduce potential process safety injuries and property loses.Improve SBUs meeting corporate HSE values. Some Good Industrial Practices from PMT can be shared across allother SBGs.

6. Team Members7. Team

ResourcesAPAC ASMs, Allen Wang (PMT PS), Site HSE leaders, Steven Eason, Toni Wenzel (PMT PS); Kent Hart (M&A);Tony Aguilera (AERO)

8. Timing: 6 months (after due training, Dec. 24, 2014)


Green Belt Tools

• Tools Utilized- Six Sigma Project Charter- Thought Process Map- SIPOC- Failure Modes Effects Analysis (FMEA)- Process Map- Control Plan


SIPOC: Process Definition

ApplyScreeningStd/ tool

Collect PSI

Documentscreening

result

D M A I C


SIPOC D M A I C


Thought Process Map D M A I C


Next steps…

• Xiaoming presented a 2-hr training to ASMs onPMTHSE805, how to screen and document theresults by early May.

• ASMs did process screening using PMTHSE805 std,1~2 processes/site/ASM by June.

• Xiaoming reviewed the screening results from allASMs by June.


Measurement System Evaluation


Measurement System Evaluation – Phase 1

Site/ASM Accuracy rate (%) Items Y rated N Items N rated YSHAero 84.6 Q19, Q20, Q23, Q24 NA

NT 69.2 Q5, Q6 Q9, Q12, Q19, Q20, Q24, Q25CS 88.5 Q5, Q13, Q23 NALY 84.6 Q5, Q13, Q14, Q26 NAGZ 84.6 Q2 Q15, Q16, Q26XA 76.9 Q16, Q23 Q5, Q8, Q13, Q24

Average 81.4 Most freq. errors: Q5, Q13, Q23, Q24


FMEA:


The Work Process


Improvement – Develop Screening Tool


Measurement System Evaluation - using tool

Measurement System EvaluationSite/ASM Accuracy rate (%) Items Y rated N Items N rated Y

Tianjin ECC 92.3 Q9 Q8Xiamen (CH28) 96.2 Q12Shengzhen 88.5 Q12, Q15, Q9Maxon (WGQ), ECC 96.2 Q20Suzhou Aero 92.3 Q2, Q16Tianjin HPS 100Zhongshan 100

Average 95.1 Most freq. errors: Q9, Q12


Process Control Plan

Project: PSM Applicability Screening to determine covered processesCore Team: APAC ASMs Date (Orig): 9/9/2014Key Contact: Xiaoming Zeng, Steven Eason

Date (Rev):

Process Process Step PotentialFailure Mode

PotentialFailure Effects Process Specification Measurement

TechniqueSample

SizeSample

FrequencyControlMethod

ReactionPlan

PSM ApplicabilityScreening to determinecovered processes

Using thescreening tool &having recordreviewed andarchived

unidentifiedprocess safetyrisks

Safety incidentReported

All sites shall comply withcorp. standardHSEMS805 and its tooland record sheet

internal audit All OneHON sites

annually andrelevantprocesschanges

MOC review,PSM auditand SAT

Createaction planto addressauditfindings.


Documentation

• Project Charter:

• Green Belt Tools:

Microsoft OfficeWord Document

Microsoft OfficeExcel 97-2003 Worksheet


THANK YOU