Contents and control measures for on-site management in chemical plants

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Definition of on-site management: On-site management refers to the use of scientific management systems, standards, and methods to carry out rational and effective planning, organization, coordination, control, and monitoring of various elements at the production site. These elements include people (workers and managers), machinery (equipment, tools, work fixtures), materials (raw materials), processes (processing and testing methods), the environment, and information. By doing so, these elements are brought into a harmonious state, thereby achieving high quality, efficiency, low consumption, balance, safety, and civilized production. The aspects of on-site management in chemical plants: In on-site management, there are five elements that require attention; these are also the five key factors mentioned in the management of industrial manufacturing enterprises, namely people, machines, materials, methods, and environment. 1. “People,” that is, human management. On-site management ultimately boils down to managing people. For new employees, a preliminary plan for assigning them to specific positions is established first, followed by a period of training in supporting roles. During the adaptation period, the level of responsibility should be the primary criterion for evaluating the employee, with a comprehensive assessment taken into account based on the employee’s operational skills and proficiency, in order to determine the appropriate position for them. For those who are initially found unfit for the position, their overall capabilities can be improved through training, re-education, and other means in order to enable them to meet the requirements. If they are no longer competent, employment will be declined. In daily production, managers should pay special attention to communicating with employees, using incentives such as praise, encouragement, and rewards to boost their confidence and enthusiasm for work. 2. “Machinery” refers to the management of mechanical equipment. Mechanical equipment is the material basis for chemical plants to carry out production activities. Based on the complexity of equipment maintenance, a \"equipment responsibility card\" should be customized for each piece of equipment, with a designated person assigned to be responsible for it. The responsible departments should conduct on-site management inspections from time to time, and establish a corresponding reward and punishment system to help each person in charge of the equipment develop a good habit of maintaining it proactively. During shift handovers, employees must keep records of the operating status of the machinery and equipment; any abnormalities in its operation can be reported and addressed promptly. In addition, regular training sessions on machine operation or theoretical training should also be organized to ensure safe operation. 3. “Materials” refers to the management of raw materials. Material management is a fundamental aspect in chemical production. Professional training should start with the material receipt personnel, so that they become familiar with the production process, understand the chemical and physical properties of each type of material, and are able to calculate accurately the amount of materials needed for a day. Materials that are not suitable for storage must not remain in the workshop; they should be taken and used immediately. Material pickers must conduct timely inspections of the raw materials in the warehouse, and it is strictly prohibited to bring substandard raw materials into the workshop. To this end, a dedicated assessment system should also be established to foster a diligent and meticulous work attitude among employees. 4. “Method”, namely the operating procedure or manual – the operating procedure serves as a guide for carrying out the operations. The responsible department should assign experienced veteran operators to provide hands-on guidance to the new employees until they fully understand and master the skills. To reduce safety risks, the responsible department also conducts irregular inspections based on original records and display recorders, reminding operators to remain vigilant at all times and to ensure that their operations comply fully with the regulations. For each different position, specific criteria for evaluating performance should be established; there should be a brief evaluation once a week and a more thorough evaluation once a month. Rewards and penalties are determined in accordance with the rules set out in these evaluation criteria, thereby further enhancing the attention to detail among operators during their work processes. 5. “Environment” refers to environmental management; the environment can have a direct impact on safe production. It is necessary to incorporate the 5S management philosophy of \"sorting, setting in order, cleaning, polishing, and discipline,\" starting with on-site management. By conducting self-inspections and mutual inspections, appropriate rules can be established based on the actual conditions of the workshop. The standards for arranging various supplies and tools have become a kind of *habit. The responsible department should encourage employees to actively participate in the \"suggestions for improvement\" initiative, to identify and explore various effective suggestions for enhancing on-site management, and to analyze, refine, and implement these suggestions in order to achieve continuous improvement. Measures for effective on-site management: 1. Enhance awareness and focus on solidifying management. For the on-site management of chemical plants, it is necessary to establish a system to guide employees’ mindset and to work diligently to strengthen management. First is the shift of the center of gravity downward. In line with the principle that \"problems should be resolved at the equipment itself and focus should be placed on the work site,\" team leaders should go to the relevant workshops in person to provide direct supervision, strengthen inspections of key equipment and production processes, and eliminate various potential hazards as soon as possible, right at the site. Second, strengthen implementation. Focusing on the production workshops, the system of requiring managers to be on duty on weekends is strictly implemented, with an emphasis on identifying potential hazards on site, improving production management, and enforcing labor discipline. Third, pay close attention to the site. In addition to carrying out regular on-site inspections, team leaders are also responsible for checking the performance of shift supervisors, team safety officers, inspectors, control room operators, etc., as well as overseeing those who work in positions such as freezing stations and forklift operations, to ensure that 100% of employees are present at their posts. Fourth, focus on rectification. On a regular weekly basis, equipment officers, safety officers, and workshop supervisors conduct comprehensive on-site inspections of various installations, and any issues identified are required to be rectified within a specified time frame. Fifth, strict attention must be paid to quality. Strengthen the control and monitoring of key parameters in the manufacturing process, enforce strict process discipline, and meet customers’ quality requirements ； Conduct quality inspections on a daily basis to promptly understand the quality status of products ； Strictly enforce the \"Raw Materials and Product Quality Standards\" to prevent substandard materials from entering the production process, thereby ensuring stable quality. 2. Improve technical capabilities to ensure safe production. Skilled and proficient abilities determine the production efficiency and safety of chemical plants. First, carry out labor competitions in depth. Labor competitions such as “reducing costs and increasing efficiency” and “fighting high temperatures to achieve high yields” are organized among the operating teams. Each team formulates assessment methods based on competition criteria related to production safety, output, and quality; they actively identify gaps, strive for better control, and compete to be the best, ensuring that their output exceeds the set targets month after month. Second is the gradual transfer of production pressure. Production targets and responsibilities are broken down and quantified for each team, with target assessment agreements signed at various levels. Through daily announcements of production volumes and consumption levels, evaluations during competition weeks, and rewards given at the end of each month, teams are motivated to strive to meet or exceed these targets. This creates an incentive mechanism in which production volume, efficiency, and revenue are interrelated, thereby fully stimulating the enthusiasm of managers and employees to increase production and helping to achieve new heights in output for the facilities. 　 3. Manage equipment and facilities properly to improve corporate efficiency. Equipment and facilities are the main reliance for employees to carry out production activities. Regular maintenance of equipment and machinery is a key aspect of operations in chemical enterprises. To ensure that production and maintenance activities can proceed simultaneously, a comprehensive management approach that integrates central control, inspections, instrumentation, maintenance, and technical personnel has been adopted, based on the actual conditions of the production workshops. This approach enables precise management and full-process monitoring of critical equipment and essential pumps. The control operator should monitor the screens in order to fully assess the operating status of the equipment, not missing any minor issues or potential problems, thus ensuring that the equipment operates under optimal conditions ； The inspection staff carry out on-site inspections every hour as required, focusing on monitoring key operational parameters such as the equipment’s temperature, oil level, and pressure. Any issues detected are addressed promptly to prevent abnormalities from developing ； Redesign the inspection routes for critical equipment and other important devices, focusing on monitoring changes in the temperature of various rotating equipment, as well as in the cooling water and lubricating oil systems, and doing everything possible to reduce the temperature of these devices. 4. Control the on-site environment and strengthen organized management. To create a favorable working environment, it is important to focus on the following three tasks: classify items on site into three categories – those with high usage frequency, those with moderate usage frequency, and those with low usage frequency. Commonly used items should be placed in an appropriate location, ensuring both safety and ease of use ； For items that are not used frequently, convenient shelves can be set up for storage ； Unnecessary items must be thoroughly removed from the site. Establish reasonable storage areas for special items. Chemical hazards present at the production site (such as various types of oils, harmful gases, paints, solvents, etc.) must be handled in strict accordance with relevant regulations; it is not allowed to stock them in excessive quantities or to place them randomly. 5. Strengthen safety management to ensure order in production. Safety education is carried out through various means, such as encouraging employees and their relatives to sign \"family agreements\" and \"spousal agreements\" on safe production. Activities such as the \"three types of encouragement\" – where parents encourage their children, spouses encourage each other, and children encourage their parents – as well as safety reminders based on the principle of \"give one thing, suggest three things, and avoid five things\" – are implemented to effectively ensure accident-free safe production. On-site management is an important part of chemical plant management; the quality of this management and its level directly affect the safety and stability of the entire production process in chemical enterprises. Therefore, in an environment where market competition among enterprises is becoming increasingly fierce, it is crucial to strengthen on-site management in chemical plants.