Guest Post by Bill Pomfret (first posted on CERM ® RISK INSIGHTS – reposted here with permission)
Investigations of industrial accidents have found that a large number occurred during an interruption of production while an operator was trying to maintain or restart production. In each case the dangerous situation was created by a desire to save time and ease operations. In each case, the company’s safety rules were violated.
The best and most redundant safety layers can be defeated by poor or conflicting management practices. Numerous examples have been documented in the chemical industry. One accident in a polymer processing plant occurred after operations bypassed all alarms and interlocks to increase production by 5%. In another, interlocks and alarms failed—at a normal rate—but this was not known because management had decided to eliminate regular maintenance checks of the safety instrumentation.
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