Process safety performance indicators (PSPI) play a critical role in identifying early warning signs before an unplanned event occurs. One of the most common weaknesses we observe across the sites we support is ineffective data collection, specifically failing to record, analyse, and act upon information that highlights emerging risks.
Even organisations without a formal process safety management system usually collect some safety-related data. However, this is often limited to lagging indicators, such as the number of unplanned events. By the time these metrics change, the opportunity to prevent the incident has already passed.
Leading vs Lagging Process Safety Performance Indicators
Lagging indicators tell you what has already gone wrong. Leading process safety performance indicators, on the other hand, provide insight into what is being done to prevent incidents before they happen.
Effective leading indicators give leadership teams and budget holders confidence that controls and mitigations are functioning as intended. Without this visibility, decision-makers cannot allocate resources effectively or intervene at the right time.
Leadership presence on site is also a powerful leading indicator. A lack of engagement often reflects a wider disconnect between senior management and the workforce.
Examples of Effective Process Safety Performance Indicators
For process plants, PSPI commonly include data from:
- Maintenance activities and overdue inspections
- Equipment failures and condition monitoring
- Safety-critical equipment testing
- Behavioural safety observations
- Reporting of unsafe acts and conditions
On one site we support in the Scottish Borders, a workforce of just 16 people now reports over 30 behavioural safety observations per month. Each observation represents an opportunity to reduce risk and improve workplace safety, and the results speak for themselves.
Why Closing Actions Is a Key Leading Indicator
Another frequent issue is the failure to close out actions from meetings, audits, or interventions. Action tracking is itself a valuable process safety performance indicator. Reporting a deviation is only the first step; if it is not corrected, the benefit of reporting is lost.
Using PSPI to Drive Improvement
Hazard studies help define what controls should be in place, but PSPI demonstrate whether those controls can be relied upon when needed. As organisations review performance and plan for the year ahead, focusing on meaningful PSPI is essential.
Avoid relying on data that masks underlying issues. Those problems will resurface later, often with greater consequences.
How OTECSA Can Help
OTECSA supports organisations by providing independent insight into process safety performance and facilitating Management Review meetings to analyse PSPI effectively.
If you want to strengthen your approach to process safety performance indicators, contact our team to find out how we can help.