Performance evaluation of integrated resilience engineering factors by data envelopment analysis: The case of a petrochemical plant

Petrochemical units are potentially prone to incidents that have catastrophic consequences such as explosion, leakage of toxic materials, and the stoppage of the production process. Resilience engineering (RE) is a new method that can control incidents and limit their consequences. It includes top-level commitment, reporting culture, learning, awareness, preparedness, and flexibility. However, this study introduces a new concept of RE (referred to as integrated RE or IRE) which includes the above factors in addition to self-organization, teamwork, redundancy and fault-tolerant. This study evaluates performance of IRE in a petrochemical plant through considering the obtained data from questionnaires and data envelopment analysis (DEA) approach. Moreover, the performance of RE and the new IRE are compared and discussed. The results show that although there is a strong direct correlation between the DEA results in two frameworks, the mean scores of efficiency in IRE is slightly higher than RE. This is the first study that introduces an integrated approach for RE. In addition, this study is amongst the first ones that examine the behavior of resilience engineering by DEA. Moreover, the superiority of IRE is shown through robust statistical analysis.     

Identification of managerial shaping factors in a petrochemical plant by resilience engineering and data envelopment analysis

Resilience engineering (RE) is a novel approach that is capable of controlling and limiting incidents and accidents. This study identifies managerial shaping factors in a petrochemical plant by RE and data envelopment analysis (DEA). To do this, a standard questionnaire containing resilient factors is completed by managers of a petrochemical plant. Then, the best DEA model is selected based on average efficiency and statistical test. In addition, sensitivity analysis are performed to identify the most important shaping factors. Reporting culture, management commitment, and preparedness are identified as the most important factors in this paper, respectively. Finally, the proposed model is validated and verified through statistical experiment. The proposed approach would help managers to have a comprehensive understanding of the plant with respect to the RE. To the best of our knowledge this is the first paper that examines resilient shaping factors in a petrochemical plant with respect to management and organization by DEA.     

Measuring and analyzing adaptive capacity at management levels of resilient systems

Resilience engineering (RE) is capable of handling disruptive events and controlling their consequences in process industries such as petrochemical plants. This study aims at analyzing the level of adaptive capacity and identifying effective factors on developing adaptive capacity in the organizational structure of process industries. The data of this study were obtained through direct observation and a structured questionnaire in a petrochemical plant. Managers at all levels participated in the survey. Data envelopment analysis (DEA), which is a mathematical approach, was used to compute and analyze the role of the factors contributing to adaptive capacity. The results indicated that reporting safety issues played a central role in enhancing adaptive capacity at all management levels. Both middle management and low-level management emphasized the importance of management commitment, whereas top-level management considered flexibility as a vital factor in managing disruptions and reducing accidents. The findings of this study could be useful for managers and other decision-makers to improve safety in process industries.     

Continuous performance assessment and improvement of integrated HSE and maintenance systems by multivariate analysis in gas transmission units

In this study, an integrated “Health, Safety, and Environment (HSE)” and maintenance systems are presented. Multivariate analysis is used for continuous performance assessment and improvement of these systems. The two subjects of “Maintenance System” and “HSE” have been individually investigated several times in different studies. However, few studies have been done to integrate these two systems and provide an integrated system for their implementation. This study evaluates current maintenance and HSE systems of a Gas Transmission Unit by Data Envelopment Analysis (DEA) and Principal Component Analysis (PCA). Moreover, decision making units (DMUs) are examined and ranked. Employees are considered as DMUs. This is done through investigating and measuring their efficiencies and identifying the inefficient and less-efficient units. Since an increase in the number of inputs does not lead to an increase in the number of outputs with the same scale, an output-oriented DEA with a Variable Returns to Scale (VRS) is used. The Fuzzy DEA (FDEA) is also used in this research to decrease uncertainty existing in qualitative indicators and human error. Finally, suggestions are given to improve those DMUs. The managers and employees of the gas transmission unit constitute the statistical population of the study. To achieve the objectives of this study, standard questionnaires with respect to HSE and Maintenance system are completed by operators. The proposed approach would help policy makers and top managers of Gas Transmission Company to have a more comprehensive and thorough understanding the working conditions with respect to the maintenance and HSE features.     

An entropy-based TOPSIS approach for analyzing and assessing crisis management systems in petrochemical industries

Crisis management systems should be assessed and updated in petrochemical industries due to hazards, such as fire and explosion. Successful crisis management systems can protect both personnel and property in the petrochemical industries. The present study aimed to assess crisis management systems of five petrochemical plants in terms of three aspects, including organizational aspects, human aspects, and technical aspects. A questionnaire was designed, encompassing 34 items to cover all three aspects at both management and staff levels. A multi-criteria decision making (MCDM) approach, including the entropy method and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS), was used to analyze the collected data. The outcomes of the entropy method indicated that organizational and human aspects had the greatest influence on crisis management systems of the plants with 58% and 49% importance at management and staff levels, respectively. The crisis management systems of the investigated plants were ranked and analyzed using the TOPSIS approach. The findings of this study could assist managers and other decision-makers to address the issues of crisis management systems in petrochemical industries.     

A framework for resilience assessment in process systems using a fuzzy hybrid MCDM model

Resilience engineering (RE) has recently emerged as a novel safety management paradigm in socio-technical organizations. It is believed that RE is more compatible with the characteristics of complex socio-technical systems. The multicriteria nature and the presence of both qualitative and quantitative latent factors make RE substantially more complex especially in quantifying and modeling aspects. To address this issue, the present research aims to develop a fuzzy hybrid multicriteria decision-making (MCDM) model for quantifying and evaluating resilience using the fuzzy Analytic hierarchy process (F-AHP) and fuzzy VIKOR (F-VIKOR) techniques. Initially, an evaluation framework including six resilience indicators and 43 sub-indicators was established. Afterward, the F-AHP method was used to determine the weight of the resilience indicators, while the F-VIKOR method was employed to rank the resilience performance of the different operational units. To present the model capability, we evaluated the resilience of a gas refinery as a typical instance of socio-technical systems. The findings revealed the performance level of resilience indicators in all units of the studied refinery and their ranking based on the computation of the index value (Qi). With respect to the Qi values, the best and worst performance of units from the resilience perspective was specified. Results indicate that the proposed model can serve as an effective evaluation approach in complicated systems and can be used to effectively design strategies to improve system safety performance. To the best of our knowledge, this is the first study that evaluates the resilience using the VIKOR and AHP in a fuzzy environment in the process industry.     

Evaluation and improvement of a method for assessing HSMS from the resilience engineering perspective: A case study of an electricity distributor

This article presents an evaluation and proposals for improving a method for assessing health and safety management systems. This method takes resilience engineering (RE) as its underlying philosophy and was originally devised and tested in a case study of a manufacturing plant. Four main changes were proposed in comparison with the original version of the method: (a) a framework for assessing the use of RE principles more systematically; (b) guidelines for developing an action plan as a result of the assessment; (c) re-organization of the data collection tools in order to increase their ease of use; and (d) procedures for facilitating the assignment of scores to the items assessed. The evaluation of the method, which was not restricted to the changes described in this article, was conducted based on seven criteria for evaluating safety assessment tools. Both the evaluation and the impact of the changes are discussed based on a case study, in which the method was applied in a company that distributes electricity.     

A neuro-fuzzy algorithm for assessment of health,safety, environment and ergonomics in a large petrochemical plant

Process plants such as petrochemical units have been continuously trying to improve Health, Safety, Environment and Ergonomics (HSEE) programs. This study proposes an adaptive network-based fuzzy inference system (ANFIS) for assessment of HSEE programs in a petrochemical plant. The proposed neuro-fuzzy approach is applied to a set of operators in the petrochemical unit to show its applicability and superiority. To achieve the objectives of this study, standard questionnaires with respect to HSEE are completed by operators. The average results for each category of HSEE are used as inputs and accomplishment of HSEE programs is used as output for the algorithm. Moreover, this algorithm is used to rank operators performance with respect to HSEE. Finally, the algorithm identifies efficient operators with respect to HSEE. This is the first study that introduces an intelligence algorithm for assessment and improvement of HSEE program in a petrochemical plant.     

Relation between senior managers’ safety leadership and safety behavior in the Chinese petrochemical industry

Senior managers in organizations are authorized and obliged to maintain organizational safety. However, to date, little research has considered the relation of senior managers' safety leadership to safety behavior. This study addresses this gap by using path analysis to confirm the validity of a hypothetical model that relates six dimensions of senior managers' safety leadership to two safety behaviors through the safety climate in the petrochemical industry. A questionnaire survey was sent randomly to workers (other than senior managers) in two petrochemical companies in China, and data from 155 usable responses were compiled for the path analysis. Results indicate that in the petrochemical industry, senior managers' safety leadership has a positive impact on safety behavior, and the safety climate plays an intermediary role between them. From the perspective of the dimensions of senior managers' safety leadership and safety behavior, safety concern has the greatest positive effect on safety compliance. Moreover, safety vision has the greatest positive impact on safety participation, whereas safety inspiration and safety awards and punishment have negative effects on safety compliance. Personal character does not directly influence any dimension of safety behavior but indirectly does so by influencing the safety climate. On the basis of these results, measures of improving senior managers' safety leadership in the petrochemical industry are presented to help improve the overall safety performance of the industry. A new view is provided for the petrochemical industry in China to suggest that senior managers’ safety leadership can be treated earnestly.     

A safety culture maturity model for petrochemical companies in Brazil

A framework to measure safety culture maturity in the Brazilian oil and gas companies was formulated based on the model of Hudson (2001). Following a review of the safety culture literature, a questionnaire was designed to measure five aspects of organisational safety indicative of five levels of cultural maturity. The questionnaire was completed by the safety managers of 23 petrochemical companies based in Camacari, Bahia, Brazil and they were interviewed one month later. The reliability of the questionnaire was tested by asking the same questions in an interview and comparing the results (alternate forms reliability). The correlation coefficients between the questionnaire and interview scores on each dimension ranged from r = 0.7 to 0.9, demonstrating good reliability of the measures used. The research findings demonstrated that the 23 companies studied showed characteristics of different levels of safety culture maturity. Most scores were at the level of proactive. The model of Hudson (2001) and the revised framework and questionnaire were found to be practical to use, making it possible to identify levels of safety culture maturity in the context of the Brazilian petrochemical industry.     

基于有界数据包络分析(DEA)模型的应急避难场所效率评价

应用数据包络分析(DEA)方法,针对应急避难场所规划建设和运营维护两种情况,分别建立以建设成本和运营成本为输入指标,以服务性、可达性、安全性为输出指标的效率评价指标体系,并选择有界DEA模型,分层次对应急避难场所的投入产出效率进行评价。实证案例表明,临时和中长期避难场所比短期避难场所更容易获得较高的DEA效率;位于区域内部、交通便利的应急避难场所DEA效率较高;提高应急避难场所的综合利用水平,更有利于提高其DEA效率。     

系统操作者与管理者行为的博弈演化与收益分析*

为研究工程项目系统中,操作者安全行为与管理者奖惩行为的相互博弈情况,确定操作者和管理者收益,提出博弈演化与收益分析方法。操作者代表系统实际使用者,行为包括安全和不安全行为;管理者代表系统管理者和所有者,行为包括奖励和惩罚行为。确定方法的基本参数;研究博弈演化过程的博弈逻辑关系,从悲观和乐观角度研究二者不同行为相互作用后的收益关系,给出操作者收益和管理者收益的逻辑表达式。结果表明:方法能得到博弈过程演化结果,同时能根据收益结果表达式判断博弈胜出方。     

Challenges in building resilience engineering (RE) and adaptive capacity: A field study in a chemical plant

Safety issue in a chemical plant is absolutely critical because loss of control can result in a catastrophic consequence which is not limited to the boundaries of the plant. Thus, a risk assessment system is required for (a) preventing accidents by anticipation, (b) surviving disturbances by recovery, and (c) handling disruptive events by adaptation. RE is a proactive approach claiming to achieve all these objectives. The present research tries to identify challenges in the procedure of building RE and its adaptive capacity in a chemical plant. Primary data were collected through on-site observations and interviewing personnel. The results indicated the main challenges could be classified into nine categories of: lack of explicit experience about RE, intangibility of RE level, choosing production over safety, lack of reporting systems, ‘religious beliefs’, out-of-date procedures and manuals, poor feedback loop, and economic problems. Finally, it is concluded that the management insight about safety in such systems should avoid hindsight bias and tend to create foresight. Changing this insight can lead to achieve high reliability and resilience in the plant.     

A method for assessing health and safety management systems from the resilience engineering perspective

This article introduces a method for assessing health and safety management systems (MAHS) that has two innovative characteristics: (a) it brings together the three main auditing approaches to health and safety (HS) – the structural approach (which assesses the system prescribed), the operational approach (which assesses what is really happening on the shop-floor) and the performance approach (which assesses the results of performance indicators); (b) it emphasizes the resilience engineering perspective on HS, which takes into consideration four major principles (flexibility, learning, awareness, and top management commitment). Such principles underlie seven major assessment criteria, which in turn are divided into items (e.g. hazard identification from a resilience perspective is an item that belongs to the criteria of production processes). The items are sub-divided into statements, which are the requirements that should be assessed based on interviews, analysis of documents and direct observations. Within the 112 requirements proposed, 38 of them have clear links with at least one out of the four resilience engineering principles adopted. The remaining requirements are based on traditional assumptions underlying the so-called best practices of HS management. The results of the assessment for each item are expressed by a score on a scale of compliance with the established requirements, ranging from 0% to 100%. The specific score within that scale is obtained from tables used to assess applications for the Brazilian national quality award. The MAHS was tested in a case study that was carried out in a factory that manufactures automobile exhaust systems, located in Brazil.     

Applications of resilience engineering principles in different fields with a focus on industrial systems: A literature review

This paper reviews literature that addresses applications of resilience engineering principles to various fields. Recently the concept has attracted great attention from a technical and industrial perspective. The primary focus of this paper is to review the resilience engineering applications to industrial systems with the purpose of applying them to the chemical industry. A systematic review is performed to classify peer-reviewed journal papers that are associated with resilience engineering applications into three categories: industrial systems, ecological systems, and interlinked systems. The literature in the category of industrial systems is further divided based on the type of approaches such as field studies, case studies, methodologies, and mathematical modeling. After thoroughly analyzing the literature, four key research areas are identified: Considering socio-technical factors for resilience assessment efficiently; Inculcating the possibility of multiple disasters in resilience assessment; Design optimization for resilience enhancement; Efficient restoration strategies. All these research areas have not been explored exclusively for chemical facilities to a great extent. It is concluded that if these research areas are addressed appropriately, it would help in triggering the research pertaining to the application of resilience engineering principles in chemical facilities.     

RANDAP: An integrated framework for reliability analysis of detailed action plans of combined automatic-operator emergency response taking into account control room operator errors

Automatic process control and control room operators supervision/intervention in an emergency are of critical importance in major hazard industries. These combined operator and automatic actions are defined in Detailed Action Plans (DAP). A framework has been proposed for analyzing the reliability, and hence the likelihood of success, of DAPs. The Reliability Block Diagram technique is utilized for modeling the reliability of integrated automatic-operator emergency actions. The focus is on incorporating operator's operational and cognitive errors in the process/equipment reliability analysis. For this purpose, the human reliability analysis method SPAR-H is utilized. The proposed framework was used for analyzing emergency response DAPs of a real process plant in order to check and improve its applicability. It is argued that the presented framework facilitates the DAP assessment process by performing Task Analysis, modeling the detailed tasks as well as reliability analysis, thereby uncovering the shortcomings of the designed DAPs. Besides, it provides a very effective, transparent tool with insight into improvement areas and directions for improving the reliability of DAPs.     

An adaptive neural network algorithm for assessment and improvement of job satisfaction with respect to HSE and ergonomics program: The case of a gas refinery

Researchers have been continuously trying to improve human performance with respect to Health, Safety and Environment (HSE) and ergonomics (hence HSEE). This study proposes an adaptive neural network (ANN) algorithm for measuring and improving job satisfaction among operators with respect to HSEE in a gas refinery. To achieve the objectives of this study, standard questionnaires with respect to HSEE are completed by operators. The average results for each category of HSEE are used as inputs and job satisfaction is used as output for the ANN algorithm. Moreover, ANN is used to rank operators performance with respect to HSEE and job satisfaction. Finally, Normal probability technique is used to identify outlier operators. Moreover, operators with inadequate job satisfaction with respect to HSEE are identified. This would help managers to see if operators are satisfied with their jobs in the context of HSEE. This is the first study that introduces an integrated ANN algorithm for assessment and improvement of human job satisfaction with respect to HSEE program in complex systems.     

区域轨道交通系统节点重要度及故障恢复研究

为提高区域轨道交通系统(RRTS)正常运营下的可靠性和故障情况下的弹性,分析区域轨道交通网络(RRTN)的拓扑特性,构建拓扑结构弹性评价模型,实现突发条件下系统弹性的定量评价;提出一种基于系统弹性的结构评价方法,根据节点重要度评价,识别出系统关键节点;应用弹性损失三角形,进行多种故障情况下系统最优恢复策略研究。结果表明:RRTN在Space L模型下具有无标度网络特性;系统弹性分析结合科普兰评分法,可以提高RRTS节点重要度评价的准确性;最优故障恢复策略从全局角度寻求不同恢复策略下系统弹性的最大值,优化了RRTS结构弹性和系统恢复能力。     

A new approach for layout optimization in maintenance workshops with safety factors: The case of a gas transmission unit

In this study, an Integrated Simulation-Data Envelopment Analysis (DEA) approach is presented for optimum facility layout of maintenance workshop in a gas transmission unit. The process of repair of incoming parts includes various operations on different facilities. The layout problem in this system involves determining the optimum location of all maintenance shop facilities. Layout optimization plays a crucial role in this type of problems in terms of increasing the efficiency of main production line. Standard types of layouts including U, S, W, Z and straight lines are considered. First, the maintenance workshop is modeled with discrete-event-simulation. Time in system, average waiting time, average machine utilization, average availability of facilities, average queue length of facilities (AL) and average operator utilization are obtained from simulation as key performance indicators (KPIs) of DEA. Also, safety index and number of operators are considered as other KPIs. Finally, a unified non-radial Data Envelopment Analysis (DEA) is presented with respect to the stated KPIs to rank all layouts alternatives and to identify the best configuration. Principle Component Analysis (PCA) is used to validate and verify the results. Previous studies do not consider safety factor in layout design problems. This is the first study that presents an integrated approach for identification of optimum layout in a maintenance workshop of gas transmission unit by incorporating safety and conventional factors.