Process Safety Management (PSM) & Safety Audit Case Study – Sigachi Industries Limited

Project Number: 25-770.20.04-sil-jgi-psma

PSM Audit Serial No.: 04

• Project Overview

A comprehensive Process Safety Management (PSM) & Safety Audit was conducted for the Dahej manufacturing facility to evaluate the effectiveness of existing safety systems and compliance with applicable standards.

The audit was carried out in alignment with OSHA 29 CFR 1910.119, IS 14489:2018, and relevant NFPA guidelines, covering multiple safety domains including process safety, operational practices, emergency preparedness, and electrical safety.

The study involved a detailed review of documentation, site inspections, and interaction with plant personnel to assess implementation of safety systems and identify opportunities for enhancement.

• Objective
• To assess compliance with 14 elements of PSM
• To evaluate implementation of safety systems and procedures
• To identify strengths and opportunities for improvement
• To enhance process safety performance and risk management practices
• To support continuous improvement in safety culture.

• Methodology

The overall methodology followed during audit is as below:

• Opening Meeting
• The audit scope, objective, methodology and audit schedule was discussed by auditors with auditee during opening meeting.
• The manufacturing process and existing system was explained by auditee to auditors
• Examination
• Compliance review of all elements as per Annexures. Wherever applicable, Procedure/Guideline/Document, Training matrix, MIS, Compliance Audit etc. is reviewed of each element.
• Site Round
• Site round in various department for observing any lagging and good practices implemented by organization
• Closing Meeting
• Closing meeting was carried out after completion of the audit
• The audit observations, recommendations and elements compliance report were discussed in the meeting

• Key Distinctive Characteristics
• Holistic PSM Evaluation covering all 14 OSHA elements
• Multi-Segment Audit Approach integrating operational and process safety aspects
• Inclusion of Combustible Dust Hazard Assessment (NFPA 652/660)
• Focus on Ignition Source Control (static, electrical, hot work)
• Integration of Indian & International Standards (IS, OSHA, NFPA)
• Risk-Based Recommendation Framework (High / Medium / Low prioritization)

• Key Outcomes
• Comprehensive Assessment of PSM Framework across all key safety elements
• Enhanced Visibility of Safety System Effectiveness and operational practices
• Identification of Opportunities for Strengthening Safety Culture and Ownership
• Improved Understanding of Critical Risk Areas including emergency response and change management
• Structured Recommendations Developed with risk-based prioritization for phased implementation
• Framework Established for Continuous Monitoring and Improvement of safety performance.

• Conclusion

The PSM & Safety Audit provided a structured evaluation of the facility’s safety management systems and operational practices. The study highlighted the importance of integrating process safety elements with day-to-day operations and strengthening organizational safety culture.

The findings emphasize the need for enhanced alignment between procedures, training, and on-ground implementation to ensure sustained safety performance. Implementation of the recommendations will support improved compliance, strengthen risk control measures, and enhance overall process safety maturity of the facility.