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BASF Streamlines Plant Safety Processes Across Global Operations with Standardized Risk Assessments
Technology Category
- Analytics & Modeling - Process Analytics
- Application Infrastructure & Middleware - Data Exchange & Integration
Applicable Industries
- Chemicals
Applicable Functions
- Discrete Manufacturing
- Quality Assurance
Use Cases
- Predictive Maintenance
- Process Control & Optimization
Services
- System Integration
- Training
The Challenge
BASF, the world’s largest chemical producer, was facing challenges in managing plant risks and safety processes. The company was using Word, Excel, or specialized desktop software to document process hazards, leading to inconsistencies in documentation across the global organization. Staff members were using different languages for classification and different methods for HAZOP assessments and data collection. This lack of consistency limited the visibility of BASF managers across facilities and hindered comparisons of issues and safeguards. Comparisons had to be done 'intellectually', by experienced staff reviewing documents that were up to 300 pages long, which was inefficient, time-consuming, and labor-intensive.
About The Customer
BASF is the world’s largest chemical producer with 2014 sales approaching €75 billion. The company operates on the principle of combining economic success with environmental protection and social responsibility. This German-based company is highly focused on the need for its operations around the world to follow strict, well-defined processes that ensure plant and worker safety as well as protecting nearby communities and ecosystems. As part of its commitment to continuous improvement, BASF embarked on a project to streamline the documentation and management of risks associated with Safety, Health & Environment (SHE).
The Solution
BASF implemented the Stature system for risk assessment, process hazard analysis (PHA), and action item tracking. The company trained 1,600 staff members across Europe, Asia, and the Americas to use the system within the first nine months of implementation. Staff in all locations now enter data into a single template that uses standardized language and measurements. The system has enabled BASF to build a central risk knowledge base and gain better visibility across the organization. Managers can now see the status of items and prioritize workloads for the next few years. The system also facilitates the revalidation process, setting all necessary dates and giving BASF staff an overview of plans and dates.
Operational Impact
Quantitative Benefit
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