Process Safety Management (PSM) is the recognized system for the prevention and mitigation of major chemical-related incidents. Six Sigma methodology was utilized to analyze the operational elements of PSM to determine the areas needing improvement and to measure initial and post-improvement capability indices.

The outcomes of the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) process focused on the fundamental elements of PSM: Process Safety Information, Process Hazard Analysis, and Operating Procedures. The Process Map reinforced the interconnection of the PSM elements. Data from audits and investigations clearly supported the focus on those fundamentals. 3M corporate and business PSM leadership participated on the Six Sigma project team and provided additional input to the process.

This paper discusses how Six Sigma tools were used to develop improvement and control plans both at the corporate level and at 15 selected facilities.