Operational Discipline in Steel Industry...

Operational Discipline in Steel Industry Operational discipline means complying with a set of ‘well thought out’ and ‘well defined’ processes, and consistently executing them correctly. Striving to achieve operational excellence is one of the most important contributors to the steel industry’s sustainable performance and growth. Steel organization which reach for a higher level of operational excellence reap numerous benefits namely (i) a systemic, evolving and effective approach to its operations (ii) a continually productive and innovative workforce, and (iii) an organization which consistently achieves sustainable growth and increasing valuation. It is not uncommon to confuse operational discipline with operational excellence. While the two are closely linked, yet the latter cannot be realized without the former.  Operational discipline is but one important component among others which one can find on the path of the operational excellence. DuPont defines operational discipline as ‘the deeply rooted dedication and commitment by every member of an organization to carry out each task the right way every time’. In short, operational discipline can be stated as ‘everyone in the organization doing it right every time’. It means complying with a set of well thought out and well defined processes, and consistently executing them correctly. It is an essential ingredient when trying to achieve operational excellence. Operational discipline provides an organized and systematic way to complete tasks and implement operational changes through a fundamental set of procedures which are specific to the steel organization’s unique product. Regardless of the final products of the steel plant, operational discipline increases reliability and decreases the risk of the occurrence of a high magnitude incident. This is much easier said than done. However, building a culture in the organization around the pillars of operational discipline is the most effective way towards the achievement of this...

Management of an Organization and Management Techniques...

Management of an Organization and Management Techniques Management of an organization is not a simple activity. On the contrary it is quite complex. Both internal and external factors affect the organizational functioning. Further there are several areas and elements which are required to be managed. Sometimes functioning of an area may appear to be in conflict with the functioning of other area. Smooth functioning of the organization depends on how the management of these different areas and elements are conducted. There are specific management techniques for each area and element. There are other techniques which may encompass entire organization. If these techniques are followed, it aids the proper and healthy functioning of the organization. Management of an organization (Fig 1) can be broadly divided into two areas. These areas of management are (i) management of organizational internal elements which have impact on the organizational functioning, and (ii) management of organizational functions where the organization comes in contact with external agencies. Internal organizational elements for management normally include (i) operational management which is the key to the existence of the organization, (ii) financial management for making the organization healthy financially, (iii) human resource management which deals with the management and development of the employees, (iv) management of organizational future which takes care for the future of the organization in the context of fast changing environment, and (v) management of safety, security and welfare which takes care of the employees’ safety, protection of the organizational properties and the external needs of the employees. Organizational functions involving external agencies are (i) sales and purchase functions involving customers and suppliers, (ii) complying with regulations and laws where the organization comes in touch with regulatory authorities and government, (iii) societal functions where the organization comes in touch with society,...

Managing the Safety and Health at Workplace...

Managing the Safety and Health at Workplace  An organization’s performance depends on the performance of its employees and the employees’ performance show vast improvement if the work is carried out by them in a workplace which is safe and has a healthy environment. Safe and healthy workplaces are always the most efficient. In fact the two go hand in hand. Also, a bad accident due to the lack of safety and healthy environment at the workplace can bring a serious damage to the organization. Safety and health at the workplace is part of the organizational management, just like production and quality. Safety and health affects production, quality, and the financial results. So it is required to be managed in the same way as other aspects such as product development, distribution, marketing, sales targets or any other management issue in the organization. It is important that management plans for it, invests in it, manages it and regulates it. In short, safety and health at workplace is an intrinsic part of the organizational management. Safety and health at the workplace is essential for preventing injury and illness to the employees at the workplace. Therefore, it is about protecting the organization’s most valuable asset which is its workers. By making available safe and healthy working environment at the workplace, the organization reduces the lost work hours and hence the cost which is associated with it. It also eliminates the interruption to the operations with resultant increase in productivity and quality. A safe and healthy workplace raises employees’ morale and thus is one of the keys to organizational success. Safe and healthy workplaces have more satisfied and productive employees (i) who produce higher quality products or/and services, (ii) return to work more quickly after an injury or illness,...

Safety Management System in a Steel Plant...

Safety Management System in a Steel Plant A safety management system (SMS) is a systematic approach to managing safety, including the necessary organizational structures, accountabilities, policies and procedures. It is a systematic and explicit approach in the organization defining safety activities by which safety management is undertaken by the organizational management in order to achieve acceptable safety levels. It is a term used to refer to a comprehensive management system designed to manage the safety elements in the work place. Safety management system is a systematic approach designed to identify safety hazards and risks, control all safety elements and reduce the risks to a more acceptable manner by ensuring that the controls are effective. Safety manage system can be defined as “a businesslike approach to safety’. It is a systematic, explicit and comprehensive process for managing safety risks. As with all management systems, a safety management system provides a way for setting goals, planning, measuring the performance, control documentation and continues improvement. It becomes part of the culture, the way people do their jobs There are three imperatives for adopting a safety management system for the organization. These are ethical, legal and financial. There is an implied moral obligation placed on the management to ensure that the work activities and the place of work is safe. There are defined statutory requirements which are to be met effectively. Safety management system,  since reduces the risks in the work place,  can reduce the financial exposure of the organization by reducing the direct and the indirect costs associated with accident and incidents. To address these three important elements, an effective safety management system is to include the following. To define the organization which is set up to manage safety risks. To identify the workplace safety risks and implement suitable...

Hazard, Hazid, Hazan and Hazop – part of Safety and Risk Management...

Hazard, Hazid, Hazan and Hazop – part of Safety and Risk Management Hazard, Hazid (hazard identification), Hazan (hazard analysis), and Hazop (hazard and operability studies) are important safety and risk management techniques in the steel industry (Fig 1).  Fig 1 Safety and risk management techniques Hazards Hazard is defined as ‘a condition, an event, or a circumstance that can lead to or contribute to an unplanned or undesirable event’. Hazard is a potential cause to generate a disaster. It has got the potential to cause (i) serious harm to the individual or the environment, (ii) harm, the severity of which depends on the extent and frequency of exposure to the hazard, and (iii) harm that does not usually occur, or is not usually detectable until a significant time (years) after exposure to the known hazard. Any activity, procedure, plant, process, substance, situation or other circumstance that has the potential to cause harm constitutes a hazard. Hazards are logically classified in the same way as the disaster events are classified.  Since a hazard exists because it may result into a disaster, it is usually viewed as natural based, human systems based, or conflict based.  Not every hazard results into a disaster, but every disaster is the result of a hazardous condition, whether or not that condition was recognized in advance of the event. Hazards are normally not identical, not uniform, not exclusive, and not transposable. They are not uniform in their range of occurrence, impacts, or timelines. They have got non identical pattern of development. Hence each hazard is to be understood in the context of its time and place. One hazard generally does not substitute for another, at least at the higher level of classification.  Since hazards are not the same, each hazard is to...