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How are cross-functional teams achieving operational efficiency and process safety targets?

Oct-2024

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Mark Schmalfeld, BASF Refinery Catalysts, mark.schmalfeld@basf.com

Refinery cross-functional teams play a crucial role in achieving operational efficiency and process safety targets. By bringing together individuals with diverse expertise from different departments, these teams can effectively address complex challenges and drive improvements. Some methods and processes that cross-functional teams employ to achieve operational efficiency and process safety targets in a refinery include:
- Collaboration and communication: Cross-functional teams promote collaboration and open communication among team members from various departments such as operations, maintenance, engineering, health and safety, and quality assurance. Regular meetings, brainstorming sessions, and sharing of information allow team members to exchange knowledge, identify bottlenecks, and develop solutions collectively.

- Process mapping and analysis: Cross-functional teams analyse existing processes by mapping out workflows, identifying inefficiencies, and pinpointing areas for improvement. They evaluate process steps, equipment, and resource utilisation to identify opportunities for optimisation and streamlining.

- Root cause analysis: When incidents or deviations occur, cross-functional teams can conduct root cause analysis to understand the underlying causes. They use techniques such as the five Whys, fishbone diagrams, or fault-free analysis to identify the primary and contributing factors. This analysis helps in developing effective corrective and preventive actions to enhance process safety and prevent recurrence.

- Continuous improvement initiatives: Cross-functional teams are effective in driving continuous improvement initiatives by implementing methodologies such as Lean Six Sigma or total productive maintenance (TPM). These methodologies aim to eliminate waste, reduce variability, improve equipment reliability, and enhance overall operational efficiency.

- Standardisation and best practices: Cross-functional teams work towards standardising processes and implementing best practices across the refinery. They identify and document successful approaches and develop guidelines or standard operating procedures (SOPs) that promote consistency, efficiency, and safety.

- Training and skill development: Cross-functional teams recognise the importance of training and skill development to ensure that employees have the necessary competencies to achieve operational efficiency and maintain process safety. They collaborate with the human resources department to identify training needs, develop training programmes, and facilitate knowledge sharing among team members.

- Performance monitoring and metrics: Cross-functional teams establish key performance indicators (KPIs) and metrics to measure progress towards operational efficiency and process safety targets. Regular monitoring of these metrics allows teams to identify deviations, track improvements, and make data-driven decisions for further enhancements.

- Change management: Cross-functional teams facilitate change management by involving stakeholders, communicating the need for change, and addressing resistance. They develop change management plans, ensure proper training and support during implementation, and evaluate the effectiveness of the changes made. Change management processes are critical to ensuring a safe operating environment in a refinery.

By leveraging these methods and processes, cross-functional teams in a refinery have proven to be more successful in achieving operational efficiency and process safety targets than separate, more ‘siloed’ teams. Their collaborative approach, combined with a focus on continuous improvement and effective communication, drives positive results and promotes a culture of safety and efficiency throughout the organisation.

Oct-2024