CASE STUDY

Poultry feed group sees major compliance wins with PTW system

Summary

This UK based poultry feed manufacturer improved safety and efficiency with the Pisys PTW system

Background

Our client, a medium-sized feed milling company in the UK, specializing in high-quality poultry feed, employs approximately 300 people across six sites. The company operates five feed mills and one extrusion plant, which vary in size from single production lines with a couple of grain silos to extensive facilities with multiple production lines, several storage areas, silos, engineering teams, and transport departments. Running 24/7 to support the poultry rearing industry, the company is a critical component of the UK food chain, ensuring a consistent supply of essential feed. The company’s HSE manager spoke to us about their issues and how they used Pisys PTW to address them.

Challenge

In 2020, the company recognized significant limitations in its paper-based permit to work (PTW) system, which had several drawbacks:

  • Compliance and Regulation: Ensuring that all regulatory and compliance requirements were met was challenging with a paper system, leading to potential gaps in documentation and oversight.
  • Contractor Management: Managing and verifying contractors’ compliance with safety standards and approval processes was cumbersome and prone to errors.
  • Visibility and Control: With operations spread across six sites, maintaining visibility and control over all work permits was difficult, making it hard to monitor ongoing tasks and ensure they did not interfere with each other.
  • Simultaneous Operations (Simops): Coordinating simultaneous operations at large sites was particularly problematic, as there was no easy way to visualize where different tasks were being carried out, increasing the risk of conflicts and safety issues.

Solution

After evaluating several options, the company chose the Pisys Permit to Work system due to its user-friendly interface, adaptability, and cost-effectiveness. The implementation of the Pisys system included several key steps and features:

Customization and Adaptability:

  • The Pisys system was easy to learn and teach, which facilitated a smooth transition from the paper-based system.
  • The company customized the system by creating a Point of Work Risk Assessment (POWRA) for non-routine tasks. This customization used an unused panel within the system, allowing engineers and mill staff to thoroughly assess tasks outside of regular work hours.

Integration with Approved Vendor List:

  • The system was integrated with the company’s approved vendor list. This integration ensured that permits could not be issued to non-approved contractors, enhancing contractor management and site safety by preventing unauthorized access.

Permit Plot Plans:

  • Larger sites implemented plot plan maps showing where permits were active. This feature provided a visual overview of ongoing tasks, which was essential for managing simultaneous operations and preventing task interference.

Remote Access and Centralized Control:

  • The Pisys system allowed for remote access to permits, providing centralized and instant visibility of work packets across all six sites. This feature enabled management to scrutinize permits remotely, ensuring full and accurate completion and identifying areas where additional coaching on safety procedures was needed.

Result

The implementation of the Pisys PTW system brought about significant improvements across several key areas:

Enhanced Safety and Compliance:

  • The system prevented the issue of permits if safety criteria were not met or if contractors were not on the approved list. This feature ensured that all work met regulatory and compliance standards, reducing the risk of safety incidents and non-compliance penalties.

Improved Contractor Management:

  • By integrating the PTW system with the approved vendor list, the company gained better control over contractor access and compliance. This improvement led to a higher level of safety and reduced the risk of unauthorized work being performed on-site.

Better Management of Simultaneous Operations:

  • The plot plan maps at larger sites provided a clear visual overview of where tasks were being performed, which was crucial for managing simops. This feature helped to prevent conflicts and ensure that tasks did not interfere with each other, thereby improving overall site safety and efficiency.

Centralized and Remote Oversight:

  • The ability to access and scrutinize permits remotely allowed management to maintain high standards of compliance and safety across all sites. This centralized control helped identify areas where staff might need additional training or coaching, leading to continuous improvement in safety procedures.

Operational Efficiency:

  • The transition from a paper-based system to a cloud-based PTW system streamlined operations and reduced the administrative burden associated with managing work permits. This efficiency allowed staff to focus more on their core tasks, improving overall productivity.

Conclusion The Pisys PTW system has significantly advanced the company’s operations in several critical areas. The enhanced safety, compliance, and operational efficiency achieved through this system have made a substantial impact on the company’s ability to maintain high standards and support the UK’s poultry rearing industry effectively. By providing better control, visibility, and management of work permits, the Pisys system has positioned the company for continued success and growth in the future.

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Testimonial

'Overall, the Permit to Work system has improved operational efficiency, further enhanced safety and helped us to consolidate vital data on activities across our sites, which in turn has positioned us exceptionally well for growth. Because the system is scalable it is very easy for us to add new sites and the flexibility of the configuration allows us to accommodate any type of task, so we're well placed to move forward with our plans to extend our geothermal business in the future. We're happy with the system and with the support provided by Pisys'

Rob Goodson HSEQ Specialist

Pisys Permit to work system is fully customisable and supports compliance with HSE/ISO/OHSAS Standards

It can be adapted to support your existing Control of Work or HSE Management System and is compatible with HSE Guidance on Electronic Permit to Work Systems, as per HSG250 and because existing control of work systems can be transferred onto PTW, set-up & training times are kept to a minimum. Our Permit to Work system integrates with the Action Tracker and Task Risk Manager modules of the Pisys 360 Suite.

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