Transformation of Production Control Through Risk Management

From Formal Control to Critical Risk Management

Traditional production control often focuses on compliance with federal norms and rules, overlooking actual accident reduction. With limited resources, it is impossible to control absolutely all hazards. Using the experience of a coal company, Alexander Valiev analyzes the transition to a barrier model of risk management, which allows focusing on the prevention of fatal injuries and major man-made accidents.

Barrier Model and the Bowtie Method

The new approach is based on identifying critical risks — potential hazards with the most severe consequences (for example, rock collapse or gas explosion). The speaker shows how the Bowtie method is used to determine risk factors and build organizational and technical barriers. Specific checklists are developed for each barrier, according to which engineering and technical personnel conduct regular inspections.

Digitalization: From Paper Checklists to a Single Workspace

The implementation of the barrier model inevitably faces the problem of paper routine. Filling out checklists manually and subsequently transferring data into spreadsheets demotivates personnel and complicates analytics. The presentation details the process of integrating the analytical module and the operational management system. This made it possible to create a single digital workspace for production workers.

Now, inspections are conducted via a mobile application on certified explosion-proof smartphones directly in the mine workings thanks to an underground Wi-Fi network. If a barrier is breached, the system automatically generates a work order to eliminate the violation and transmits the data to an analytical dashboard to monitor root causes.

What you will learn from this webinar:

• How to identify critical enterprise risks and develop effective checklists for them?
• How to overcome personnel resistance when transitioning from paper inspections to digital tools?
• How to automate the issuance of work orders to eliminate violations directly from a mobile application?
• How to build a motivation system for managers for the high-quality implementation of production control?