• Shift pattern assessment

    2004 - Chemical Manufacture

    The client was planning to change from an 8 hour to 12 hour shift pattern. Also, the number of shift teams was being reduced from six to five, which resulted in employee reductions, and required changes to the way absence (e.g. sickness and holidays) was covered. This project was an evaluation of the proposed changes, including collecting views and comments from the operators being affected. Andy evaluated the planned changes to confirm the new arrangements would be acceptable from a health and safety point of view, and to provide advice about how the changes should be managed. The HSE Fatigue Index was used to evaluate the proposed new pattern. During the project, control room operators raised concerns about mental fatigue from the increased time they would be in the control room on each shift. Some other operators had physically demanding tasks and were concerned that the longer shifts would impact on their work and result in injury and physical fatigue. There was also a general concern about an ageing workforce, and how this affected shift work. The report included a qualitative assessment of the risks and advice about how they could be controlled. Advice was provided regarding human physical capabilities, nutritional requirements and how to avoid physiological fatigue.

  • Staffing assessment in support of a COMAH report

    2011 - Chemical manufacture

    The client was updating its COMAH report and recognised a need to include an objective assessment of staffing arrangements.  Andy was asked to conduct a study using the HSE method described in CRR348/2001.  He facilitated a number of workshops in order to complete physical and ladder assessments.  His report concluded that most necessary arrangements were in place, but that the details of their application was sometimes lacking.  He made recommendations to improve emergency arrangements so that prompt and effective responses would be more likely during an incident, and to review competence management programs.

  • Staffing assessments of two plants on a large petro-chemical site

    2009 - Petrochem

    The company had been through rounds of staffing reductions, change of ownership and management reorganisation. Also, the two plants in question had moved from dedicated control rooms to a shared facility.  Andy conducted separate assessments for the two plants in order to identify any common and specific concerns.  He identified a number of actions to improve the control of staffing and other human factors risks.  A number of them related to the original design of the plant.  However, a significant proportion of issues had arisen from the way various changes of plant, procedures and organisation had been managed in the past.

  • Supporting the design of a control room upgrade

    2011 - Chemical manufacture

    An existing control room was requiring a complete upgrade.  The available space was limited and the client had a number of plans for changes they wanted to incorporate.  Andy worked with the operating team and control/instrument department to define the requirements and constraints for the control room; and identified relevant aspects of standards and guidance that needed to be applied.  He produced sketches that were used as the basis for the detailed design and provided advice on subjects from room and equipment layout, furniture selection and colour schemes.