105 - Integrating HSE Into HOS

Document Owner Mishra, Rajesh
HSE Management System

Approved By Shankar, Reshmi
Level 2 Standard
Issue Date Jan 1, 2008
Effective Date Aug 25, 2014
General HSER
Rev # & Date 08 25.08.2014
Integrating HSE into HOS
Standard # 105
1.0 APPLICABILITY
1.1 This procedure is applicable to HTS, Kalyani and it establishes minimum requirements that
must be met by the site.
2.0 OVERVIEW
2.1 HOS is a comprehensive, integrated business approach to drive sustained exceptional
performance in safety, quality, delivery, cost and inventory.
2.2 It is a broad application of Lean & Six Sigma tools against a construct of standardized work,
rapid problem solving, continuous improvement and knowledge sharing.
2.3 Organization design enables and perpetuates the system through specific roles &
responsibilities for leaders, high-performance management systems, and a supportive
structure.
2.4 Early integration of HSE into HOS is critical for maximum success of both the HSE and HOS
Management Systems.
2.5 It establishes minimum requirements that must be met by all organizations that are Full
Scale Deployment Sites in the Honeywell Operating System (HOS).
3.0 DEFINITIONS
3.1 Definitions for underlined text are found at the end of this document. A master list of
definitions for all Honeywell HSEMS Standards is also available.
4.0 OBJECTIVES
4.1 To ensure the site establishes the steering team to lead the site to Phase-V.
4.2 To ensure a road map is developed with appropriate timelines and milestones to work
towards sustaining each step and work to achieve a sustained Phase-V.
4.3 To carry out a periodic review of the overall system implementation work and identify the
gaps to achieve and sustain Phase-V for the site.
5.0 RESPONSIBILITIES
5.1 Site Leader is responsible for ensuring that HSE is fully integrated into the Honeywell
Operating System.
5.2 Site HOS Leader is responsible to ensure that HSE is being integrated into HOS and that
the site HSE Leader is involved in the integration process.
5.3 Health, Safety & Environmental (HSE) Leader is responsible for providing technical and
regulatory expertise and assisting in HOS integration, process development,
implementation, training, mentoring, and assessment.
5.4 Line Manager or Supervisor is responsible to ensure that all HSE aspects of the Honeywell
Operating System are followed by their employees.
5.5 Employees are responsible to comply with applicable HSE requirements of the Honeywell
Operating System.
© Honeywell Technology Solutions Lab Private Limited, 2014

CAUTION: Printed copies of this document is uncontrolled unless issued by HSE department.
Please visit http://teamsites.honeywell.com/sites/HTS-HSE/default.aspx for current version.
Page 1 of 8
Level 2 Standard
General HSER
Rev # & Date 08 25.08.2014
Standard # 105
5.6 Contractors are responsible for following the requirements of the Honeywell Operating
System.
6.0 REQUIREMENTS
6.1 Integrating HSE Into HOS - Phase I
6.1.1 HOS Steering Team - The site HSE Leader must be a full member of the facility HOS
Steering team. This includes a requirement to attend the Steering Team’s meetings
and play an active role in the implementation of HOS.
6.1.2 Integrating HSE Into HOS Workshop – In a Full Scale Deployment Site, the site HSE
Leader must attend the full 2-day Integrating HSE into HOS Workshop. To insure that
the Integration of HSE into HOS is fully accomplished and effective, it is recommended
that the site HOS Leader attend this training, as well.
6.1.3 HSE into HOS Training Modules – Once the HSE Leader has attended the “Integrating
HSE into HOS Workshop”, planning should begin on:
6.1.3.1 When the HSE-HOS Training modules will be used
6.1.3.2 Who will do the training, and
6.1.3.3 Who the target audience will be for each session, etc.
6.2 Phase II
6.2.1 HSE Self Assessment Tool – If the HSE SAT is greater than six months old, it must
be updated to reflect the current state of HSE at the facility, or an up-to-date open
corrective action plan is available.
6.2.2 HSE Metrics - the tracked HSE Metric for HOS will be the site’s HSE Audit or SAT
(Self Assessment Tool) score, whichever is more current. The Corporate SAT Tool
will be continuously open for input throughout the year and the Audit/SAT Score is a
measurement of the HSE Management System that is currently in place at a site, it is
a much better metric for judging HSE progress.
6.2.3 Strategy Deployment – As part of the formal HOS Goal Deployment Process that is
initiated in Phase II, each site must establish a 3 – 5 year management plan to
improve the HSE Management System. The objective of this plan shall be to achieve
a verifiable HSE SAT score of 85. In addition, an AOP SAT Objective will be
established each year that is designed to incrementally improve the site’s SAT score,
so that the targeted 85 score is achieved during the course of the management plan.
This AOP SAT Objective will be entered into the Corp. HSE Event Tracking System
(ETS) each year. It is expected that the site will use standard HOS tools, such as an
X-Matrix, A-3s and the Targets to Improve (TTI) Review Process to help them achieve
their AOP SAT Objective.

Page 2 of 8
Level 2 Standard
General HSER
Rev # & Date 08 25.08.2014
Standard # 105
6.2.4 Kaizen – There should be evidence that a significant number of Kaizens have had an
HSE related focus. Over a period of time, HSE related Kaizens should account for
approximately 10 % of all Kaizens done within the site. This could involve any area of
HSE, including Sustainability improvements such as: reduced energy or water use,
increased recycling, a reduction in hazardous waste or the use of hazardous
chemicals, etc.
6.3 Phase III
6.3.1 Integration of HSE into HOS Training - Provide site wide training on why and how we
are Integrating HSE into HOS, using Integrating HSE into HOS - Module I.
6.3.2 5s Process – Include HSE related issues during the training and implementation of the
5s process.
6.3.3 Standardized Work for Leaders – Insure that HSE specific activities are included in
the Standardized Work for all members of the Site Leadership Team, Managers,
Supervisors, and Team Leaders.
6.3.4 HSE Accountability – A process exists to ensure that all Site Leaders are held
accountable for accomplishing their required HSE Standardized Work.
6.3.5 Rapid Problem Solving – HSE issues are included in the training for Rapid Problem
Solving. HSE Rapid Problem Solving triggers to drive 5-Why Analysis in solving day-
to-day HSE issues. Evidence is available that 5-Why Analysis is used for solving day-
to-day HSE related problems and not just during Incident Investigation.
6.3.6 Visual Management – HSE is integrated into Visual Management using more than
just TCIR and First Aid rates. In particular, visuals illustrating critical HSE areas such
as: on-time closure of corrective actions, PPE requirements, an HSE compliance
calendar, the number and types of training sessions conducted, audits and inspections
performed, completed pre-use checklists, etc. are regularly used throughout the
facility. As appropriate, these visuals should be added to the Tier Boards for visible
tracking and appropriate discussions.
6.4 Phase IV
6.4.1 Standard Operating Sheets – HSE must be fully integrated into the Standard
Operating Sheets (SOS). This includes:
6.4.1.1 Identifying all key HSE points in each step of the SOS and identifying these items
by the use of a green cross symbol.
6.4.1.2 Identifying all task related Personal Protective Equipment on the SOS.
6.4.1.3 Studying each cell or work area to reduce the use of energy, water, hazardous
chemicals, the generation of hazardous waste, or increase recycling. If, as a
result of an HOS work area redesign or Kaizan activity, any one of these
environmental “sustainability” aspects is enhanced by at least 15%, a Green Dot
may be placed at the top left corner of the SOS to indicate that a significant
environmental improvement has been accomplished through HOS.
Page 3 of 8
Level 2 Standard
General HSER
Rev # & Date 08 25.08.2014
Standard # 105
6.4.1.4 Requiring an HSE signature on all SOS’s that are related to operations,
maintenance and any other HSE critical tasks. This signature indicates that the
local HSE professional agrees that HSE has been properly integrated into the
SOS.
6.4.2 Hazard Screening – A Hazard Screening tool is used by the cell members whenever
changes are made that could have an impact on HSE. The completed Hazard
Screenings should either accompany the Standard Operating Sheets or be readily
available for quick reference.
6.4.3 Total Productive Maintenance – Including HSE in the TPM process ensures that we
are running a safe and environmentally sound operation. Original Equipment Manuals
and other instruction documentation should be consulted to determine the
recommended TPM practices for HSE.
6.4.4 Autonomous Maintenance & Compliance –
6.4.4.1 Properly trained employees should be involved in ongoing (i.e. daily, weekly,
monthly, as appropriate) pre-use checks of all HSE related safety devices such as,
interlocks, light curtains, emergency stops, ventilation systems, etc. Original
Equipment Manuals and other instruction documentation should be consulted to
determine the recommended daily or weekly checks for safe operation.
Documentation of these checks must be available within the cell.
6.4.4.2 Properly trained employees should also complete inspections, checks and other
activities for their work area that are required by regulation or internal standard.
Examples include: fire extinguisher inspections, eye wash and safety shower
inspections, ladder inspections, hazardous waste container inspections, forklift
inspections, etc. Documentation of these inspections must be maintained
according to Honeywell or legal requirements.
6.5 Phase – V
6.5.1 Behavior Observation Process – A Behavior Observation Process has been
identified by the site and training on this process has begun within a few target cells.
Note: The completed requirements for the HOS Behavior Observation Process are
included in HOS 26.
6.6 Contractors
6.6.1 All contractors working at a HTS site must follow the requirements outlined in this
procedure.
6.6.2 It is the responsibility of the HTS Contractor Coordinator to inform contractor
management of this procedure during either the annual contractor meeting or the pre-
work safety meeting.
6.6.3 It is the responsibility of the HTS Contractor Coordinator to verify that the contractor’s
employees are following all approved HSE related HOS Procedures.

Page 4 of 8
Level 2 Standard
General HSER
Rev # & Date 08 25.08.2014
Standard # 105
6.6.4 Any contractor employee who violates approved HSE related HOS Procedures will not
be allowed to continue working at the site.
6.7 Training: All appropriate employees shall receive documented initial training on Integrating
HSE into HOS. This training will include:
6.7.1 Specific areas and methods of integration.
6.7.2 The employee’s role in the integration process.
6.7.3 A demonstration of understanding the principles of Integrating HSE into HOS.
6.7.4 This training will occur prior to the employee beginning work in an area that is in a full
scale implementation mode.
6.7.5 All training documentation (dates, content, trainer, signatures, etc.) will be maintained
on file or in a computer database and be available for review.
6.8 Enforcement
6.8.1 Where either an employee or supervisor willfully violates HSE related HOS
Procedures, appropriate disciplinary action will be taken.
6.8.2 Any action taken should be in accordance with local disciplinary procedures and must be
documented.
6.9 Audit and Program Review: To assure that HSE is being properly integrated into HOS, its
application shall be frequently reviewed. These reviews must occur on a regular basis and
cover all areas that are in full scale implementation.
6.9.1 Phase Gate Reviews
6.9.1.1 Phase IV Gate Review – An external HSE Leader, generally from the SBG, who is
knowledgeable in HSE-HOS Integration, participates in the Phase Gate Review to
ensure that all required HSE Integration points have been successfully
accomplished. In addition, the site’s most recent Audit or SAT score must meet the
established AOP SAT Objective.
6.9.1.2 Phase V Gate Review into Bronze - A member of the Corporate HSE staff
participates in the Phase Gate Review to ensure that all required HSE Integration
points have been successfully accomplished. This review could be conducted
through a conference call in advance of the formal exit. In addition, the site’s most
recent Audit or SAT score must meet the established AOP SAT Objective.
6.9.1.3 Silver Certification – To achieve HOS Silver Certification an on-site verification
audit must be conducted, in advance of the formal exit, by a member of the
Corporate HSE staff to insure that the site has attained a verified Audit or SAT
score of 80, or higher. For sites that do not achieve an 80 during the verification
audit, re-audits will only be done once every six months. (Note: The only waiver of
this verification requirement is if the site has had a Corporate Audit or SAT
verification visit within the last 12 months, which resulted in a verified score of at
least 80.)
Page 5 of 8
Level 2 Standard
General HSER
Rev # & Date 08 25.08.2014
Standard # 105
6.9.1.4 Gold certification – To refer 7.2
6.9.2 Self Assessment Tool (SAT)
6.9.2.1 As part of the HSE Self-Assessment, the organization shall perform a documented
annual evaluation of the Integration of HSE into HOS as per HOS 14.
6.9.2.2 The results of the annual self-evaluation shall be communicated to all appropriate
levels of management.
6.9.2.3 All actions that are necessary to improve the process must be documented in the
Event Tracking System and completed in a timely manner.
6.9.3 Corporate HSE Audit Process
6.9.3.1 The Corporate HSE Audit Team will assess the site’s compliance with this
procedure during Corporate HSE Audits.
6.9.3.2 All HSE Audit Recommendations will be tracked to completion through the Event
Tracking System.
6.9.3.3 Training records will be reviewed to determine if all required training was
conducted and properly attended will be reviewed.
6.9.3.4 Review the availability of all the documents and records required to be maintained
by this procedure.
6.9.3.5 Discrepancies between the requirements outlined in this Procedure and the
realities at the site may result in either recommendations or suggestions contained
in the HSE Audit Report.
6.9.3.6 Deficiencies that are identified during the Corporate HSE Audit must be
addressed in a timely manner, with appropriate documentation maintained.
7.0 REFERENCE DOCUMENTS
7.1 Integrating HSE into HOS Workshop – Training Materials
7.2 HSE Requirements for HOS Gold
7.3 HOS Silver verification process for HSE
7.4 Hoshin Plan
8.0 ATTACHMENTS
8.1 Standard Operating Sheet
9.0 REVISION LOG

Revision Section Revision
Revised By Description of Change
Number Number Date

Page 6 of 8
Level 2 Standard
General HSER
Rev # & Date 08 25.08.2014
Standard # 105
00 All Manoharan D A 01-01-2008 New release

01 All Manoharan D A 25-02-2009 Yearly review, No changes
02 All Manoharan D A 15.10.2009 1. New format & New numbering system followed
03 All Manoharan D A 19.01.2011 Revised HSE Metrics Requirements for Phase Gate
Reviews and the Strategy Deployment Section.
04 All Manoharan D A 19.01.2012 Site leader name changed.
05 All Manoharan D A 19.01.2013 Yearly review, No changes
06 All Manoharan D A 20.12.2013 1. Site leader Name changed
2. New numbering system followed
3. Added 4.0 Objectives of the program
4. Removed 4.1 Responsibilities from the
Requirements and Provided Separate section
5.0 And Requirements Shifted to Sec 6.0
07 All Mishra, Rajesh 01.06.2014 Half - Yearly review
Site HSE leader name changed.
08 All Mishra, Rajesh 25.08.2014 Review in line with corporate revision – HSE
requirements for Gold certification included;
HOS silver verification process included
DEFINITIONS
Autonomous Routine or minor maintenance activities completed by an operator such
Maintenance as cleaning, making adjustments, lubricating, checking guards, checking
e-stops, etc.
Behavior A process focused on observing for behaviors and providing feedback as
Observation to how the behavior was performed with the intent of increasing the
Process performance of proper behaviors.
5s A process using sort, store, shine, standardize and sustain activities to
create a safe, organized and clean work area which reduces non-value
added time in the workplace.
Full Scale HTS sites that is implementing the complete HOS Standard
Implementation Implementation Framework.
Site
Hazard Screening A basic review of a cell to identify and control possible HSE related
hazards.
Hoshin Planning A closed loop management system for identifying, focusing and linking
objectives across the organization to achieve results.
HSE Self Tool used by a HTS facility to evaluate their local HSE programs on an
Assessment Tool annual basis.
Kaizen A continuous improvement activity.
Page 7 of 8
Level 2 Standard
General HSER
Rev # & Date 08 25.08.2014
Standard # 105
Rapid Problem A problem solving approach that is focused on speed, fact finding and a
Solving sense of urgency to understand the problem so one can determine the
root cause of the problem and eliminate it.
Standard A document that details the steps to performing a routine task. Key HSE
Operating Sheets and Quality points are highlighted within the document.
Standardized Activities that have been identified as part of routine work for site
Work for Leaders leaders.
Sustainability The ability of an organization to manage its responsibility for
environmental stewardship, stakeholder engagement and the economic
prosperity of the company as well as the communities in which it does
business over the long term.
Total Productive The use of good operating or maintenance activities of equipment to
Maintenance maximize equipment life and reduce interruptions due to malfunctions.
Visual The display of information where employees can visually see what is
Management taking place in the facility. This could include the use of charts, graphs,
information tracking, procedures, signs, color coding systems, etc.

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105 - Integrating HSE Into HOS

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HSE Management System

© Honeywell Technology Solutions Lab Private Limited, 2014

© Honeywell Technology Solutions Lab Private Limited, 2014

© Honeywell Technology Solutions Lab Private Limited, 2014

9.0 REVISION LOG

© Honeywell Technology Solutions Lab Private Limited, 2014

00 All Manoharan D A 01-01-2008 New release

© Honeywell Technology Solutions Lab Private Limited, 2014

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