5s + safety finds a new home at an old refinery5s + safety finds a new home at an old refinery...
TRANSCRIPT
Damon Shodrock, CSPSafety & Security Supervisor
Calumet San Antonio Refinery
5S + Safety Finds a New Home at an Old Refinery
Company OverviewCalumet Specialty Products Partners, L.P. is a leading independent producer of high-quality, specialty hydrocarbon products. Our product lines include both naphthenic and paraffinic oils, aliphatic solvents, synthetic lubricants, asphalt, fuels, white mineral oils, waxes, petrolatums and hydrocarbon gels.
NASDAQ: CLMTHQ: Indianapolis, INFortune 500 Company: 2014 & 2015
Calumet San Antonio Refinery (CSAR) Past• Built by Howell Hydrocarbons in the 1950s
• Legacy of the AGE Ownership
• Calumet Spills April & May 2014
CSAR 2015 SAFETY IMPROVEMENT PLANSTRATEGIES TACTICSPromote Operational Excellence
1. Author and collaborate on well written procedures.2. Conduct Root Cause Analysis for significant events and drive completion of CAPA.
Foster Professional & Technical Competence
1. Deliver top quality training.2. All Operators fully trained on Emergency Response Team
(ERT).3. Launch 10 computer training center in the break room.4. Develop leadership path within the ERT.
Develop Outstanding Safety Culture
1. Launch Behavior and Conditions Observation Program.2. Launch “STOP Card” Program.
Fatality & Severe Loss Prevention
1. Conduct operational discipline gap assessment against top 10 OSHA serious violations.
2. Routinely audit facilities for vulnerabilities.
CSAR 2015 SAFETY IMPROVEMENT PLAN
CSAR Future
• High-grade solvents
• Strengthen our Community Advisory Panel (CAP)
• Continue building relationships local first responders.
• Continue building relationships w/ neighborhood groups.
April 5, 2015. San Antonio Express News. Business Section.
CSAR Future
February 15, 2016. KSAT News. 10 PM. Tim Gerber, Reporter“South Side oil refinery opens up to show off upgrades”
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Why 5S?Company Image. Increase Employee Morale. “Customers” Demand It.
(Direct Customers, ISO & VPP Auditors, etc.)Less for Regulators to Observe.Eliminates Waste/ Better Time Management. Improves Quality.
le.
The 5S's –an English “Translation”
Sort: Clear the work area
Set in Order: Designate locations
Shine: Cleanliness & workplace appearance
Standardize: Everyone doing things the same way
Sustain: Ingraining the 5S’s into the culture
Baseline Findings
Crane leaking hydraulic fluid.
Faded labels and rusty tank .
Evidence of tank overfilling.
Broken X-Ray Machine Tossed in the Control
Room Hallway.
Abandoned Chairs or Trashy Chairs?
Access to Electrical Panel Blocked.
Baseline Findings
First Attempts @ 5S at Calumet …• Refinery PPE Cabinets• LOTO Locks and Lock Box Cabinets• Loading Rack Spill Response Supplies
Photo: William Luther /San Antonio Express-News
SORT
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Sort = only what is needed in the work area. Applies to all work areas.
Set in OrderEXAMPLE: First Aid cabinet after SORT and SET IN ORDER.
ShineMore than making the work area spic and span.Shine Objectives: 1. Getting the workplace clean, 2. Maintaining its appearance, and 3. Using preventive measures to keep it clean.
Standardize• Must Have Clear Roles and Responsibilities.
• Train Personnel to Consistently Apply 5S Techniques.
StandardizeExpectations for All Employees:•No leaks, spills, or liquids found on floors. •Leaks reported and repaired.
StandardizeExpectations for All Employees:•No items stored on or around equipment.•Consolidate supplies & parts to prevent unnecessary stock.
StandardizeExpectations for All Employees:•Items not part of a ongoing job (48 hour rule) should be cleaned up and properly stored.•Every item stored should have a designated location (ex. floor marking, shelf label.)•Stored items should be stored neatly.
SustainAudit Weekly
Track Progress by Owner
Maxim Integrated Products5S Board
SustainAudit Weekly
Track Progress by Owner
Calumet San Antonio Refinery5S + Safety Checklist & Progress Board
LOCATION DATE SCORE # OF ACTIONS DATE SCORE # OF ACTIONSHazardous Waste Cage 2/18/201610.2 ± 3.1 4Rail Loading 7/22/201619.2 ± 5.0 5ULSD Unit 9/23/201619.4 ± 4.3 2Flare Safety Area 10/28/201617.5 ± 3.1 0JPTS Tank Farm 7/29/201610.4 ± 2.9 1RO Unit 11/4/201615.0 ± 2.8 1Crude Unit 10/21/201614.6 ± 3.5 2ASU Unit 10/14/201620.5 ± 3.9 3Refinery Warehouse 9/16/201611.3 ± 7.5 0300 Tank Farm 10/28/201620.6 ± 2.4 2Drum Dock 4/6/20169.8 ± 3.1 6200 Tank Farm 11/11/201620.3 ± 3.0 0Elmendorf Terminal 12/16/201619.5 ± 2.1 3400 Tank Farm 12/2/201610.7 ± 2.0 2Brooks Shop & Backlot 8/12/201615.4 ± 7.0 2South 40 9/2/20165.0 ± 4.7 4100 Tank Farm 9/9/20167.5 ± 3.5 2Cooling Towers 7/15/20167.0 ± 1.8 4SFU Unit 11/4/201622.0 ± 1.4 1Staging Lot & 430 Tanks 11/18/201615.0 ± 1.0 3Brooks Warehouse 1/6/201720.2 ± 4.2 1Brooks Lab 1/13/201718.5 ± 2.4 4Brooks Bunker Room 1/20/201712.7 ± 4.3 2Brooks Office 1/20/201711.9 ± 4.6 5Control Room 1/27/20179.3 ± 2.1 1Truck Loading Rack Office 1/27/20178.7 ± 2.3 1
Sustain = Audit & Track Action Items to Closure
Showing Pride in Our Facility Through HousekeepingSSustain = Leader Reminder & Support
After: Brooks Lab Chemical Storage Canopy and Satellite Waste Accumulation Area
Before: Safety Zone Marking
Before: Vehicle Bollard Protection
General Information
Incident Short Description: Silver Ford pickup ran through truck rack fence
Detailed Description:
at approx. 0400 hrs. a silver ford pickup truck ran through truck rack fence. As I pulled up to the loading rack I saw a silver ford pickup leaving out of the truck rack. I asked the operators what happened and they told me he just ran through the fence on the NE side of the truck rack. I called the duty manager and he called the on duty safety rep and I called SAPD Case # SAPD16120003 Officer M. Hollenbeck #370
Initial Corrective Action: called Duty Manager
Location Details
Site: San Antonio Refining
Unit:
Shift: Shift D
Area where incident took place: Truck Rack NE fence
Before: Vehicle Bollard Protection
Sustain: Overview of Roles and ResponsibilitiesEveryone: 5S becomes part of culture and is entrenched in our everyday work
Owners, Supervisors & Managers: Perform weekly audits of areas and enter action items into RegAction.
Damon Shodrock, [email protected]