TIER-3 PROCESS SAFETY EVENT MANAGEMENT IMPROVEMENT AT PT. ABC WITH LEAN SIGMA APPROACH

• Main Author: Saputra, Dicky
• Format: Theses
• Language: Indonesia
• Subjects: Manajemen umum
• Online Access: https://digilib.itb.ac.id/gdl/view/54738
• Institution: Institut Teknologi Bandung

In spite of excellent safety culture and reinforcement from the management for tier-3 reporting in an operating unit in PT ABC, one of the biggest oil company in Indonesia, there is a concern on the decreasing trend of number process safety tier-3 event report. It might indicate either good operational discipline or operator negligence to report out such event, or even other factors. To sustain and maintain the level of persistent alertness in operation particularly when the number of tier-1 or 2 are already low in that organization, the study to identify the primary cause is required to improve the tier-3 process safety event reporting system. This research will use lean sigma method to aim for improvement in percentage reported tier-3 event, its reporting lead time, and data gathering cycle time for causal analysis in PT. ABC. According to the study result, the external condition does not allow the field operator to demonstrate the tier-3 detection behavior, particularly for pressure safety valve activation. As the visibility level of its consequence is relatively low, the recognition relies on direct witness from front liners. Voluntary reporting may not be effective in this situation. Such approach will have dependency on the good quality from the individual internal factors to cope with the environment expectation. It is also identified the organization had to have several non-valueadded activities to cope with various quality of individual’s internal factor during event reporting. To have better leverage, it is more beneficial for PT. ABC to have observation-based method by having automatic detection for the occurrence of less visible Process Safety Event such as Tier-3 event. In the new process, a script to query operation data from database system will be carried out every 12 hours. It will be followed by running oracle procedure to detect any tier-3 event occurrence. Then, a scheduled script will automatically generate email notification every 24 hours to listed recipient. The notification will include necessary information about the tier-3 event for causal analysis. This IT tool has capability to automatically detect and send a report within 24 hours in the event of tier-3 occurrence. It also can provide the detail event description to avoid back and forth discussion with operation for data gathering process. The project was kicked off in June 2020 and has been progressed to control phase at the moment. The improved process has been handed over to process owner and a 12-month control monitoring is still on going to ensure the sustainability of improved process. For future improvement, it is suggested to have data analysis and prediction function to increase the value of tier-3 event reporting system.