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Session 2: Responsible Production

Company Training Course

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Contents

1.Background

2.Objectives

3.Introduction to the Responsible Production Model

4.Five steps of the Responsible Production Model

5.Introduction to mock case study

6.Topics for discussion

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Background• The Responsible Production approach is build upon a

5 step model for assisting companies to improve chemical safety management and risk communication in their organization and among their stakeholders.

• Preparedness for emergencies that may result in off-site consequences requires the development and implementation of an integrated emergency response plan, assuring the necessary linkages with the roles of relevant external stakeholders in emergency preparedness and response.

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Objectives

• To introduce participants to the 5-step approach of the Responsible Production modular approach, and present the list of tools available in the Responsible Production Toolkit.

• To introduce participants to the mock case study that may be used to support course exercises

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What is Responsible Production?

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• It is a systematic and continuous improvement approach aimed at SMEs for :– Chemical safety along the value-chain;– Understanding hazards;– Controlling chemical exposure;– Reducing accident risks;– Engaging stakeholders; and– Promoting chemical product stewardship through

risk communication aimed at preventing exposure and accidents with hazardous substances along the value chain.

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Chemical Product Stewardship

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“…the practice of making health, safety and environmental protection an integral part of the life cycle of chemical products.”

(ICCA Product Stewardship Guidelines, 2007)

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Responsible ProductionAims and Rationale

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• Need to foster safe work practices and chemical safety information along the chemical industry value chain, (involving not only the producers but also their suppliers, transporters, end customers, and other relevant business partners)

• An integrated approach to chemicals safety and chemical product stewardship can not be implemented without the identification and engagement of the relevant stakeholders along the value chain

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Responsible ProductionA focus on SMEs

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• Small and Medium Sized companies (SMEs) in many developing countries form the backbone of the industrial sectors where hazardous chemicals are manufactured, transported, repackaged and used

• SMEs can benefit from an integrated guidance on safer production and safer chemicals handling specially addressed to their needs and to the needs of their business partners along the value-chain, including end customers and the affected communities

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Introduction to the RP model

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•The Responsible Production approach includes practical guidance and tools for assisting companies in:

– identifying and understanding the hazards and risks related to the company products and operations;

– identifying opportunities for reducing risk and costs;– identifying and engaging with business partners and

communities to improve safety and preparedness for accidents with chemical products;

– promoting risk communication and product risk information along the value chain;

– training workers and business partners in chemical safety;– improving procurement systems to include chemical safety

management;– measuring and communicating performance in a transparent

way.

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Introduction to the RP model

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•The Responsible Production model :– is not meant to be a stand alone management

system. It is meant to be integrated with existing management practices and procedures already existing in chemical companies

– is not intended to replace existing practices but to provide an additional approach to managing hazards and risks, within an wider concept of “risk objects” (i.e. other stakeholders in addition to company workers, such as business partners, customers and end users, the authorities and communities may be subject to risks posed by hazards in a companies operations)

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The 5 steps of the the RP model• The RP model includes 5 steps:

• Together, these steps provide a systems approach to managing the risks and impacts associated with chemical hazards, through a CSR aligned, value-chain approach.

1. IDENTIFY RESPONSIBLE PRODUCTION ISSUES

2. GET THE RIGHT PEOPLE INVOLVED

3. DEVELOP YOUR PLAN

4. PUT THE PLAN INTO PRACTICE, TRAIN AND COMMUNICATE

5. EVALUATE HOW WELL YOU DID

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Section 1: Identify Responsible Production Issues

UNDERSTAND THE PROCESS FLOW

RISK ASSESSMENT AND PRIORITISATION

1. IDENTIFY RESPONSIBLE PRODUCTION ISSUES

STANDARDS, CODES, LAWS AND REGULATIONS

Tool 1.1 Prepare process flow chart

Tool 1.2 Chemical inventory and Hazard ClassificationTool 1.3 Identify RisksTool 1.4 Hazard Hotspots Map

Tool 1.5 Legal register

Basic Tools Advanced Tools

Tool 1.6 Hazard Classification (Control Banding)

RISK ASSESSMENTAND PRIORITISATION

CHEMICAL INVENTORY AND HAZARD CLASSIFICATION

PROCESS FLOW ANALYSIS

RISK IDENTIFICATION

STANDARDS, CODES AND REGULATIONS

LEGAL REGISTE

RHAZARDHOTSPO

TS MAP

CHEMICAL IDENTIFICATION AND HAZARD

CLASSIFICATION

OPERATIONAL PROCESSES

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Section 2: Get the Right People Involved

IDENTIFY YOUR STAKEHOLDERS

UNDERSTAND YOUR STAKEHOLDERS AND HOW THEY ENGAGE

ENGAGE YOUR STAKEHOLDERS

PRIORITSE STAKEHOLDER ISSUES

REVIEW THE ENGAGEMENT PROCESS

2. GET THE RIGHT PEOPLE INVOLVED Basic ToolsAdvanced ToolsTool 2.1 Map Stakeholders

Tool 2.2 Profile Stakeholders

Tool 2.3 Select the engagement methodTool 2.4 Plan the engagement

Tool 2.5 Prioritise issues

Tool 2.6 Review Engagement Process

REVIEW OF ENGAGEMENT PROCESS

REVIEW OF ENGAGEMENT PROCESS

AND PLAN

STAKEHOLDER ID

STAKEHOLDER ENGAGEMENT

STAKEHOLDER MAP

STAKEHOLDER PROFILES

ENGAGEMENT METHODS

ENGAGEMENT PLAN

ISSUE PRIORITIZATION

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Section 3: Develop your Plan

BUILD AND COMMUNICATE THE BUSSINESS CASE

SET CHEMICAL OBJECTIVES, TARGETS AND INDICATORS

PREPARE CHEMICAL CONTROL ACTION PLANS

DEVELOP EMERGENCIES PLAN

3. DEVELOP YOUR PLAN

DEVELOP TRAINING NEEDS ASSESSMENT AND PLAN

IDENTIFY OPPORTUNITIES FOR RISK AND COST REDUCTIONS

Basic Tools Advanced ToolsTool 3.1 Identify Actions for

Risk Reduction Tool 3.2 Risk Reduction Cost Analysis

Tool 3.3 Set goals, objectives, targets and indicators

Tool 3.5 Training plan

Tool 3.6 Emergencies plan

Tools 3.7 to 3.11 Prevent and Reduce Risk (per activity)

Tool 3.4 Chemical Control Action Plan

Tool 3.12 Business Case

IDENTIFY ACTIONS, UNDERSTAND THE COSTS AND

SET CHEMICAL OBJECTIVES, TARGETS AND INDICATORS

DEVELOP CHEMICAL CONTROL ACTION PLAN, TRAINING PLAN, AND EMERGENCIES PLAN

IDENTIFY ACTIONS FOR RISK REDUCTIONCOST ANALYSIS

SETTING GOALS, OBJECTIVES, TARGETS, AND INDICATORS

CHEMICAL CONTROL

ACTION PLANSTRAINING PLAN EMERGENCIES

PLAN

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Section 4: Put Plan into Practice, Train and Communicate

4. PUT PLAN INTO PRACTICE, TRAIN AND COMMUNICATE

TRAIN YOUR WORKERS AND BUSINESS PARTNERS

FOSTER RISK COMMUNICATION

IMPROVE YOUR PROCUREMENT PRACTICES

DEVELOP AND IMPLEMENT BEST PRACTICE PROCEDURES

Basic Tools Advanced Tools

Tool 4.1 Best Practices Procedures

Tool 4.5 Procurement Checklists

Tool 4.2 Develop Training Materials

Tool 4.3 Risk Communication

Tool 4.4 Product Risk Information

BEST PRACTICES PROCEDURES

TRAINING AND RISK COMMUNICATIONDEVELOP AND IMPLEMENT BEST PRACTICES

PROCUREMENT CHECKLIST

DEVELOPING TRAINING MATERIALS

RISK COMMUNICATION

PRODUCT RISK INFORMATION

PROCUREMENT

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Section 5: Evaluate How Well you Did

EVALUATE PERFORMANCE AND MANAGEMENT PRACTICES

COMMUNICATE PERFORMANCE

PROVIDE ASSURANCE

5. EVALUATE HOW WELL YOU DID Basic Tools Advanced Tools

Tool 5.1 Performance Assessment Tool 5.2 Management Assessment

Tool 5.3 External Communications

Tool 5.4 Independent Assurance

PROVIDE ASSURANCE

INDEPENDENT ASSURANCE

EVALUATE PERFORMANCE AND MANAGEMENT PRACTICES COMMUNICATE

PERFORMANCE

PERFORMANCE ASSESSMENT

PROTOCOL

MANAGEMENT ASSESSMENT

PROTOCOL

EXTERNAL COMMUNICATIO

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Introduction to mock case study

• Company XYZ, Ltd mixes and distributes liquid paints (inks).

• Plant site and its surroundings:

6GPL

H

LPG

Grass

350 m

450 m200 m

300 m

River

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S

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Activity and site description

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• The operations carried out on the site are limited to mixtures at ambient temperature without any chemical reaction.

• The site is composed of :– Raw materials storage: Raw materials are stored in plastic

barrels (220 L) laid out on pallets, on a specific curbed (for the collection of eventual liquid releases on the ground) ground marked area.

– Process room: where the mixtures for the paints manufacture are carried out. The mixing is undertaken in a nitrogen-inerted, stainless steel vessel.

– A washdown (washing area) for the barrels.– A laboratory, where the process control takes place.

Personnel sample and test finished products to ensure that the compositions are correct before dispatching.

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• The site is composed of (continued):– Finished products storage area: Area with filmed

containers, on standby for being dispatched. – Waste storage area. This area has a retention basin for the

capture of eventual leakages. – Open-air area for the storage of solvents in bulk : 4

reservoirs of 20 m3 in a retention basin (1 reservoir is not being used. There are also some 20 IBCc of Ethanol being stored inside the retention basin)

– A boiler room: boiler with natural gas

Plan of the site

Storageof

finishedproducts

Storage of empty barrels

Process Room

Storage of waste

Storageof teh

raw

materials

Laboratory

Boiler roomElectric room

Office

Fire resistant wall

Fire resistant wallStorage of solvent

Washdown

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The process

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1. The raw materials conditioned in barrels are conveyed by truck and are stored in the warehouse, on a specific ground marked area.

2. Then, for the manufacture of the mixture, the necessary raw materials are brought in the process room: the barrels are placed in a mezzanine and are discharged in a fixed tank. Unloading is carried out by gravity using a flexible hose. There are usually 5 to 15 barrels (220 L) of raw materials in the process room. The paint manufacture is done by continuous addition of a solvent, in the tank equipped with a mixing device. The solvent is transferred by gravity, by overhead pipelines located outside.

3. The unloading of the mixture is carried out in mobile containers: the vessel feeds a dosing device equipped with a number of valves corresponding to the number of material components. The valves are equipped with jack-valves allowing the output flow-rate control (weight control). After each use, they are washed by solvent circulation.

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The process (continued)

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4. After being closed by a lid, the paints are manually transferred into the dispatching in zone.

5. The barrels and the vessels area are washed: the operation consists in sprinkling the edges of the containers with a solvent using a steel pipe finished by a flexible PVC hose.

6. The washer is a brush that acts by friction. The operation is carried out under a closed lid. The sealing is ensured by joints and the used solvent is continuously extracted to a dedicated tank.

7. The site is heated due to a natural gas boiler

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Materials at site

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• Solvents : – Ethanol – N-propyl acetate– solvent of washing– dirty solvent

• Raw materials:– They are primarily varnish and concentrates: these

preparations are not done in the site.(these are supplied by Supplier C in plastic barrels (220 L)

– Their composition is mainly a mixture of water, waxes, resins, certain coloured pigments, and various additives. Some material are combustible and can release dangerous fumes if exposed or under fire. For example, additive ABB5 present in many formulations, is likely to generate an ammonia outburst in combustion.

– The raw material storage area has a capacity of 550 barrels

Supplier A: Ethanol and N-propyl acetate in bulk (each in road tankers of 15,000 litres)

Supplier B: Ethanol in 1,000 litres Intermediate Bulk Containers (IBC)’s

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Materials at site

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• Finished product: – Filmed pallets with paints in containers (cans) of 15, 25, and

75 Liters– There is usually an average of 120,000 Liters in the finished

products storage area

• Waste storage area:– In the waste storage area are being stored several different

types of containers and waste products, including unidentified IBCc, 220 L barrels, and several containers with damaged finished product

– There is no information of the quantities of waste materials being stored.

• Laboratory:– Small quantities of reagents and other materials, including

flammable and toxic chemicals

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Topics for discussion…

• Rationale behind each of the 5 steps in the RP model

• Benefits of the RP approach and its tools for helping companies in improving their safety practices

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Contacts