Production System Elements as a Tool for Efficient and Safe Work

Evolution of Production Systems and Safety

In today's rapidly developing world, it is not enough for companies to simply perform their basic functions. To achieve progress and stay ahead of competitors, proactivity is required — working to anticipate problems rather than reacting to incidents that have already occurred. One of the proven solutions is creating a continuous improvement system.

Alexey Mosyagin, Head of the HSE Department at Zarubezhneft-Dobycha Kharyaga, explains how to effectively combine labor productivity improvement tools with safety assurance. The presentation details the company's production system, which consists of four basic elements, and its impact on reducing the prerequisites for incidents.

Team Work Organization: Standardization and Rating

The first element of the system includes the standardization and visualization of typical operations. The goal of standardized work is to simplify and develop a unified approach to performing tasks. This saves time and is especially useful for training new employees. Standard operation cards contain a step-by-step sequence of actions, signs, and safety requirements.

The HSE department also develops its own cards for high-risk work: gas-hazardous, hot work, lifting operations, and work at height. This allows both internal employees and contractors to perform complex tasks safely and quickly.

An important part of team work organization is the monthly rating of structural divisions. Winners receive financial motivation. The occupational safety block plays a critical role in this rating: the occurrence of incidents resets the monthly rating to zero, and a fatal accident or one causing significant health damage resets the rating for the entire year. The timely implementation of production control measures and the conduct of proactive safety dialogues with contractors are also evaluated.

Workplace Organization Using the 5S System

The second element is aimed at workplace uniformity and consists of five steps: sort, set in order, shine, standardize, and sustain. Every month, a special commission inspects workplaces using checklists (about 70 items). The results of these inspections, as well as the fulfillment of the annual schedule for bringing facilities to a reference state, are taken into account in the division ratings.

Continuous Improvement System "I Have an Idea"

The third element involves all personnel, including contractors, in the improvement process across two areas: safety and production. An employee can submit an idea using a paper form on a board or electronically. Ideas are reviewed by a technical council, and points are awarded for accepted proposals, which can be exchanged for prizes (non-financial motivation). If an idea brings an economic effect, additional points are awarded.

The speaker shows by example that employee involvement in the system reaches 82%, and structural divisions — 100%. This block is also taken into account in the team rating under the "Active Position" section, which includes participation in corporate competitions such as "Best in HSE" and "Best 5S Workplace".

Lean Culture and Intervention System

The fourth element forms a lean attitude towards resources by identifying and reducing waste. Personnel actions are analyzed for value addition. Ideas aimed at saving resources and requiring significant implementation costs are formalized into separate "Lean Production" projects.

An important tool is the stop-card system — the right of every employee to intervene and suspend work upon detecting unsafe conditions or actions. Filling out stop-cards positively affects the personal rating of the employee and the rating of the division.

What you will learn from this webinar:

• How to integrate safety requirements into standard operation cards?
• How does the team rating system work and why do incidents reset results?
• How to motivate personnel (including contractors) to submit safety improvement ideas?
• How does the 5S system affect the overall efficiency and safety of production processes?
• How does the stop-card system work and how is it related to employee motivation?