Scribd Logo
Upload

Welcome to Scribd!

  • 33 views

    5S + Safety Finds A New Home at An Old Refinery: Company Overview

    Uploaded by

    Fátima Macario Monzón
    This document summarizes the implementation of 5S (Sort, Set in Order, Shine, Standardize, Sustain) practices at the Calumet San Antonio Refinery to improve safety. It describes how 5S was applied to various areas of the refinery to clean up and organize workspaces. Metrics were tracked to measure progress. Implementation of 5S practices helped standardize expectations and maintain clean and organized work areas.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    5S + Safety Finds A New Home at An Old Refinery: Company Overview

    Uploaded by

    Fátima Macario Monzón
    33 views28 pages
    This document summarizes the implementation of 5S (Sort, Set in Order, Shine, Standardize, Sustain) practices at the Calumet San Antonio Refinery to improve safety. It describes how 5S was applied to various areas of the refinery to clean up and organize workspaces. Metrics were tracked to measure progress. Implementation of 5S practices helped standardize expectations and maintain clean and organized work areas.

    Original Title

    Untitled

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document summarizes the implementation of 5S (Sort, Set in Order, Shine, Standardize, Sustain) practices at the Calumet San Antonio Refinery to improve safety. It describes how 5S was applied to various areas of the refinery to clean up and organize workspaces. Metrics were tracked to measure progress. Implementation of 5S practices helped standardize expectations and maintain clean and organized work areas.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    33 views28 pages

    5S + Safety Finds A New Home at An Old Refinery: Company Overview

    Uploaded by

    Fátima Macario Monzón
    This document summarizes the implementation of 5S (Sort, Set in Order, Shine, Standardize, Sustain) practices at the Calumet San Antonio Refinery to improve safety. It describes how 5S was applied to various areas of the refinery to clean up and organize workspaces. Metrics were tracked to measure progress. Implementation of 5S practices helped standardize expectations and maintain clean and organized work areas.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 28

    5S + Safety Finds a New Home

    at an Old Refinery
    Damon Shodrock, CSP
    Safety & Security Supervisor
    Calumet San Antonio Refinery

    Company Overview
    Calumet Specialty Products Partners, L.P. is a leading independent
    producer of high-quality, specialty hydrocarbon products. Our product
    lines include both naphthenic and paraffinic oils, aliphatic solvents,
    synthetic lubricants, asphalt, fuels, white mineral oils, waxes, petrolatums
    and hydrocarbon gels.

    NASDAQ: CLMT
    HQ: Indianapolis, IN
    Fortune 500 Company: 2014 & 2015
    Calumet San Antonio Refinery (CSAR) Past
    • Built by Howell Hydrocarbons in the 1950s
    • Legacy of the AGE Ownership
    • Calumet Spills April & May 2014

    CSAR 2015 SAFETY IMPROVEMENT PLAN


    STRATEGIES TACTICS
    Promote Operational 1. Author and collaborate on well written procedures.
    Excellence 2. Conduct Root Cause Analysis for significant events and
    drive completion of CAPA.
    Foster Professional & 1. Deliver top quality training.
    Technical Competence 2. All Operators fully trained on Emergency Response Team
    (ERT).
    3. Launch 10 computer training center in the break room.
    4. Develop leadership path within the ERT.
    Develop Outstanding 1. Launch Behavior and Conditions Observation Program.
    Safety Culture 2. Launch “STOP Card” Program.

    Fatality & Severe Loss 1. Conduct operational discipline gap assessment against top
    Prevention 10 OSHA serious violations.
    2. Routinely audit facilities for vulnerabilities.
    CSAR 2015 SAFETY IMPROVEMENT PLAN

    • High-grade
    CSAR solvents

    Future • Strengthen our


    Community
    Advisory Panel
    (CAP)

    • Continue building
    relationships local
    first responders.

    • Continue building
    relationships w/ April 5, 2015. San Antonio Express News. Business Section.
    neighborhood
    groups.
    CSAR
    Future

    February 15, 2016. KSAT News. 10 PM. Tim Gerber, Reporter


    “South Side oil refinery opens up to show off upgrades”

    9
    Why 5S?
    ¾ Company Image.
    ¾ Increase Employee Morale.
    le.
    ¾ “Customers” Demand It.
    (Direct Customers, ISO & VPP Auditors, etc.)
    ¾ Less for Regulators to Observe.
    ¾ Eliminates Waste/ Better Time
    Management.
    ¾ Improves Quality.

    The 5S's –
    an English “Translation”
    ƒ Sort: Clear the work area

    ƒ Set in Order: Designate locations

    ƒ Shine: Cleanliness & workplace


    appearance

    ƒ Standardize: Everyone doing things


    the same way

    ƒ Sustain: Ingraining the 5S’s into the


    culture
    Baseline Findings

    Faded labels and


    rusty tank .
    Evidence of tank Crane leaking
    overfilling. hydraulic fluid.

    Baseline Findings

    Abandoned Chairs or
    Trashy Chairs?

    Broken X-Ray Machine


    Access to Electrical
    Tossed in the Control
    Panel Blocked.
    Room Hallway.
    Why 5S?
    Before–Hazardous Waste Storage Room

    Why 5S?
    After–Hazardous Waste Storage Room
    First Attempts @ 5S at Calumet …
    • Refinery PPE Cabinets
    • LOTO Locks and Lock Box Cabinets
    • Loading Rack Spill Response Supplies

    Photo: William Luther /San Antonio


    Express-News

    SORT
    Sort = only what is needed in the work area. Applies to all work areas.

    17
    Set in Order
    EXAMPLE:
    First Aid cabinet
    after SORT and
    SET IN ORDER.

    Shine
    More than making the work area spic and span.
    Shine Objectives:
    1. Getting the workplace clean,
    2. Maintaining its appearance, and
    3. Using preventive measures to keep it clean.
    Before Sort, Set in Order, and Shine

    After Sort, Set in Order, and Shine


    Standardize
    • Must Have Clear Roles and Responsibilities.

    • Train Personnel to Consistently Apply 5S Techniques.

    Standardize
    Expectations for All Employees:
    •No leaks, spills, or liquids found on floors.
    •Leaks reported and repaired.
    Standardize
    Expectations for All Employees:
    •No items stored on or around equipment.
    •Consolidate supplies & parts to prevent unnecessary stock.

    Standardize
    Expectations for All Employees:
    •Items not part of a ongoing job (48 hour rule) should be
    cleaned up and properly stored.
    •Every item stored should have a designated location
    (ex. floor marking, shelf label.)
    •Stored items should be stored neatly.
    Maxim Integrated Products

    Sustain 5S Board

    Audit Weekly

    Track Progress by
    Owner

    Calumet San Antonio Refinery


    Sustain 5S + Safety Checklist & Progress Board

    LOCATION DATE SCORE # OF ACTIONS DATE SCORE # OF ACTIONS

    Audit Weekly Hazardous Waste Cage


    Rail Loading
    2/18/2016 10.2 ± 3.1
    7/22/2016 19.2 ± 5.0
    4
    5
    ULSD Unit 9/23/2016 19.4 ± 4.3 2
    Flare Safety Area 10/28/201617.5 ± 3.1 0
    JPTS Tank Farm 7/29/2016 10.4 ± 2.9 1

    Track Progress by RO Unit


    Crude Unit
    11/4/2016 15.0 ± 2.8
    10/21/201614.6 ± 3.5
    1
    2

    Owner ASU Unit


    Refinery Warehouse
    10/14/201620.5 ± 3.9
    9/16/2016 11.3 ± 7.5
    3
    0
    300 Tank Farm 10/28/201620.6 ± 2.4 2
    Drum Dock 4/6/2016 9.8 ± 3.1 6
    200 Tank Farm 11/11/201620.3 ± 3.0 0
    Elmendorf Terminal 12/16/201619.5 ± 2.1 3
    400 Tank Farm 12/2/2016 10.7 ± 2.0 2
    Brooks Shop & Backlot 8/12/2016 15.4 ± 7.0 2
    South 40 9/2/2016 5.0 ± 4.7 4
    100 Tank Farm 9/9/2016 7.5 ± 3.5 2
    Cooling Towers 7/15/2016 7.0 ± 1.8 4
    SFU Unit 11/4/2016 22.0 ± 1.4 1
    Staging Lot & 430 Tanks 11/18/201615.0 ± 1.0 3
    Brooks Warehouse 1/6/2017 20.2 ± 4.2 1
    Brooks Lab 1/13/2017 18.5 ± 2.4 4
    Brooks Bunker Room 1/20/2017 12.7 ± 4.3 2
    Brooks Office 1/20/2017 11.9 ± 4.6 5
    Control Room 1/27/2017 9.3 ± 2.1 1
    Truck Loading Rack Office 1/27/2017 8.7 ± 2.3 1
    Sustain = Audit & Track Action Items to Closure

    Sustain = Leader Reminder & Support


    Showing Pride in Our Facility Through Housekeeping
    Before: Refinery Drum Dock Random Vehicle Parking

    After: Refinery Drum Dock Accessible


    Before: Heavy Equipment Parking

    After: Heavy Equipment Parking


    Before: Refinery Drum Dock Storage

    After: Refinery Drum Dock Storage


    After: Refinery Drum Dock Storage

    Before: Tank 431 Curved Stair Treads


    After: Tank 431 Curved Stair Treads

    Before: 200 Tank Farm Walkway


    After: 200 Tank Farm Walkway

    40

    Before: Brooks Lab Chemical Storage Canopy


    After: Brooks Lab Chemical Storage Canopy and
    Satellite Waste Accumulation Area

    Before: Safety Zone Marking


    After: Safety Zone Marking

    After: Safety Zone Marking


    Before: Standardization of Swing Gates

    After: Standardization of Swing Gates


    Before: Accumulator Row Platform

    After: Accumulator Row Platform


    Before: Unit Work Permits

    After: Unit Work Permits


    Before: Vehicle Bollard Protection

    General Information

    Incident Short Description:


    Silver Ford pickup ran through truck rack fence

    Detailed Description:

    at approx. 0400 hrs. a silver ford pickup truck ran through truck rack fence. As I pulled up to the loading rack I saw a
    silver ford pickup leaving out of the truck rack. I asked the operators what happened and they told me he just ran
    through the fence on the NE side of the truck rack. I called the duty manager and he called the on duty safety rep and
    I called SAPD Case # SAPD16120003 Officer M. Hollenbeck #370

    Initial Corrective Action:


    called Duty Manager

    Location Details

    Site:
    San Antonio Refining

    Unit:

    Shift:
    Shift D

    Area where incident took place:


    Truck Rack NE fence

    Before: Vehicle Bollard Protection


    After: Vehicle Bollard Protection

    5S + Safety Can Be Fun!


    Sustain: Overview of Roles and Responsibilities
    Everyone: 5S becomes part of culture and is entrenched in our everyday work
    Owners, Supervisors & Managers: Perform weekly audits of areas and enter action items into
    RegAction.

    Damon Shodrock, CSP


    [email protected]

    You might also like