Improving Safe Working Conditions Through the Development of the Production System

Integrating Safety into the Production System: Experience of Zarubezhneft-Dobycha Kharyaga

The development of a production system is impossible without the deep integration of occupational health and industrial safety issues. In modern realities, companies are divided into reactive, responding to events that have already occurred, and proactive, working to prevent them. The transition to the second type requires a systematic approach, personnel involvement, and continuous improvement. During the webinar, Alexey Mosyagin, Head of the HSE Department at Zarubezhneft-Dobycha Kharyaga, shares practical experience in transforming the production culture in the oilfield.

The 5S System as a Tool for Identifying Preconditions for Incidents

The speaker analyzes in detail the application of the 5S standard not just as a method of organizing the workspace, but as a full-fledged safety tool. In the company, the supervision of this system is entrusted to the HSE Department, since every non-compliance with the standard (for example, cluttered aisles or improper storage of chemicals) is considered a potential precondition for an incident.

• Regular Audits: Conducted using scored checklists, which allows for an objective assessment of the condition of facilities.
• Visualization of Improvements: Departments report monthly in a "before/after" format, demonstrating real changes (for example, labeling precursors in the laboratory).
• Analytics of Violations: Identified non-conformities are classified into unsafe acts and unsafe conditions, which helps to pinpoint the causes of violations through the Nestro Data dashboard.

Personnel Involvement: The "I Have an Idea!" Continuous Improvement System

One of the key elements in developing a safety culture is motivating employees to find solutions. The presentation shows how the idea submission system works, covering both the client's and contractors' employees.

• Safety Priority: Ideas aimed at improving HSE have the highest weight coefficient when awarding points.
• Multi-level Motivation: Accumulated points can be exchanged for valuable prizes, additional paid days off, or voluntary health insurance policies for relatives. The best idea of the month is rewarded with a cash bonus.
• Practical Results: Out of more than 3,800 submitted ideas, about 1,700 have been implemented. Examples include optimizing the gas supply setpoint control system and modernizing the testing of alarm systems.

Organization of Crew Work and Visual Management

To maintain involvement at a systemic level, the company uses a comprehensive approach to organizing the work of structural divisions.

• Department Ranking: The monthly assessment takes into account participation in the 5S system and idea submission. The winners of the quarter receive a substantial cash bonus, which creates healthy competition.
• Standard Operating Procedures (SOPs): Visualized step-by-step instructions (for example, for targeted briefing before gas-hazardous work) are coordinated with the HSE Department, ensuring a balance between speed and safety of work execution.
• Visual Performance Management (VPM) Boards: A tool for holding regular planning meetings, allowing every employee to see the connection between their daily tasks and the company's key performance indicators.

Assessing Maturity and Overcoming Resistance

The implementation of new tools always faces resistance. The speaker shows by example how the company overcame these difficulties by integrating new requirements into the ranking and financial motivation system, gradually forming a habit and understanding of the value of innovations. The assessment of the production system's development level is carried out using internal audits and the "Barometer" system, which allows tracking dynamics and planning further improvements.

What You Will Learn from This Webinar:

• How to adapt the 5S standard for the needs of the HSE department and reduce the number of preconditions for incidents?
• How to build a working safety idea submission system and how to motivate personnel?
• How to use department ranking to increase involvement in HSE issues?
• How to visualize workflows using SOPs and VPM boards to improve safety?
• How to overcome personnel resistance when implementing new production system tools?