1. This presentation is for planning and study purposes only. Proposals and options contained herein are subject to review, approval and any legally
required notice, collective bargaining and consultation obligations.
Improve Identification of
PSM Covered Processes
GBPL: XiaoMing Zeng
Corp. HSE, APAC
2014
Status: Certified

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

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Project Charter
Element Project Information
0. Project Title Improve Identification of PSM Covered Processes
1. Area of Focus
or Function:
PSM, Corp. HSE;
Scope: Geographically APAC One-HON sites where with ASM supports; Operating modes of existing assets and
acquired assets including JVs where HON has operational control; Business scope includes all SBGs (including TS
for confirmation);
2. Problem
Statement
Some SBG do not recognize PSM covered processes on their facilities, esp. those outside of PMT
manufacturing sites. Thus Process Safety is not managed in a consistent and effective way on those sites
missing the identification. Examples include the Tier 1 PS incident Event ID: 398014 with root causes
identified as not PSM covered process.
3. Benefit to
Customers:
The customers of this project include those SBG leaders, SBG site leaders, Site HSE leaders and the impacted
personnel 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 can
be improved. Adequate PSM system if identified for the covered processes will reduce the likelihood and loses
of PS events.
4. Project
Metrics: Metrics: Baseline Goal Entitlement Units
Rate
(Successful Id of PSM applicability)
Not currently
measured
90% Goal %
Coverage
(Screening sites in the region)
Not currently
measured
100% Goal %
5. Business
Impact
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 all
other SBGs.
6. Team Members
7. Team
Resources
APAC 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)

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Preliminary – not final – no decision will be taken without satisfaction of any applicable consultation or negotiation requirements.
Green Belt Tools
• Tools Utilized
- Six Sigma Project Charter
- Thought Process Map
- SIPOC
- Failure Modes Effects Analysis (FMEA)
- Process Map
- Control Plan

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SIPOC: Process Definition
Apply
Screening
Std/ tool
Collect PSI
Document
screening
result
D M A I C

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SIPOC D M A I C

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SIPOC D M A I C

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SIPOC D M A I C

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Thought Process Map D M A I C

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Thought Process Map D M A I C

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Thought Process Map D M A I C

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Next steps…
• Xiaoming presented a 2-hr training to ASMs on
PMTHSE805, how to screen and document the
results by early May.
• ASMs did process screening using PMTHSE805 std,
1~2 processes/site/ASM by June.
• Xiaoming reviewed the screening results from all
ASMs by June.

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Measurement System Evaluation

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Measurement System Evaluation

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Measurement System Evaluation – Phase 1
Site/ASM Accuracy rate (%) Items Y rated N Items N rated Y
SHAero 84.6 Q19, Q20, Q23, Q24 NA
NT 69.2 Q5, Q6 Q9, Q12, Q19, Q20, Q24, Q25
CS 88.5 Q5, Q13, Q23 NA
LY 84.6 Q5, Q13, Q14, Q26 NA
GZ 84.6 Q2 Q15, Q16, Q26
XA 76.9 Q16, Q23 Q5, Q8, Q13, Q24
Average 81.4 Most freq. errors: Q5, Q13, Q23, Q24

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FMEA:

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The Work Process

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Improvement – Develop Screening Tool

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Measurement System Evaluation - using tool
Measurement System Evaluation
Site/ASM Accuracy rate (%) Items Y rated N Items N rated Y
Tianjin ECC 92.3 Q9 Q8
Xiamen (CH28) 96.2 Q12
Shengzhen 88.5 Q12, Q15, Q9
Maxon (WGQ), ECC 96.2 Q20
Suzhou Aero 92.3 Q2, Q16
Tianjin HPS 100
Zhongshan 100
Average 95.1 Most freq. errors: Q9, Q12

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Preliminary – not final – no decision will be taken without satisfaction of any applicable consultation or negotiation requirements.
Process Control Plan
Project: PSM Applicability Screening to determine covered processesCore Team: APAC ASMs Date (Orig): 9/9/2014
Key Contact: Xiaoming Zeng, Steven Eason
Date (Rev):
Process ProcessStep
Potential
Failure Mode
Potential
Failure Effects
ProcessSpecification
Measurement
Technique
Sample
Size
Sample
Frequency
Control
Method
Reaction
Plan
PSM Applicability
Screening to determine
covered processes
Using the
screening tool &
having record
reviewed and
archived
unidentified
process safety
risks
Safety incident
Reported
All sites shall comply with
corp. standard
HSEMS805 and its tool
and record sheet
internal audit All One
HON sites
annually and
relevant
process
changes
MOC review,
PSM audit
and SAT
Create
action plan
to address
audit
findings.

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Documentation
• Project Charter:
• Green Belt Tools:
Microsoft Office
Word Document
Microsoft Office
Excel 97-2003 Worksheet

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