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From Data to Decisions: How AI and FACILEX® Transform SEG Sampling into a Strategic Best Practice

Industrial Hygiene SEG sampling is a proven way to protect workers from daily exposure risks, but its full value emerges when integrated into Process Safety Management (PSM). This post explores how combining AI agents with FACILEX® transforms SEG sampling from routine monitoring into a strategic best practice. By automating assignments, validating data, identifying exposure trends, and linking results directly to PHAs, MOCs, and incident investigations, organizations can move from data to decisions—strengthening compliance, workforce protection, and executive visibility within their PSM programs.

The best Process Safety Management (PSM) systems are built not just on compliance, but on integration and continuous improvement. Industrial Hygiene (IH) practices—especially Similar Exposure Group (SEG) sampling—play a critical role in protecting workers from daily exposure risks. But the challenge for many organizations is ensuring that SEG sampling data doesn’t sit in silos, disconnected from broader PSM systems.

This is where artificial intelligence (AI) and FACILEX® technology can transform SEG sampling from a routine monitoring activity into a strategic best practice that directly informs process safety decisions.

Bridging IH Data and Process Safety Management

SEG sampling provides the raw data needed to assess worker exposures. But without structured management and analysis, the value of this information is limited. FACILEX®, with its foundation in risk-based process safety management, provides the environment for:

  • Assigning sampling responsibilities.
  • Managing workflows and follow-up actions.
  • Storing exposure data in a central repository linked to PHAs, MOCs, and incident investigations.

An AI agent layered on FACILEX® can take this one step further, transforming raw IH data into actionable insights for both safety professionals and executive management.

Why AI-Enabled SEG Sampling Is a Best Practice

When AI is integrated with FACILEX® for IH SEG sampling, organizations gain:

  • Smarter assignments – AI can auto-generate SEG sampling schedules based on regulatory requirements, process risks, and past trends.
  • Data validation and efficiency – Automated ingestion and quality checks ensure sampling data is accurate, consistent, and accessible.
  • Real-time insights – Trends and anomalies in exposure data are identified early, preventing risks before they escalate.
  • Closed-loop integration – Sampling data is automatically linked to PHAs, MOCs, and incident investigations, ensuring no disconnect between exposure monitoring and process safety decisions.
  • Executive visibility – FACILEX® dashboards, enhanced with AI analysis, turn technical IH results into clear performance indicators and risk summaries for leadership.

Aligning AI and FACILEX® with PSM Elements

An AI-enabled IH program directly strengthens core PSM and Risk-Based Process Safety elements:

  • PHA: Validates exposure assumptions with real-world sampling results.
  • MOC: Ensures equipment or process changes don’t create unintended IH risks.
  • Incident Investigation: Provides exposure baselines to support root cause analysis.
  • Continuous Improvement: Tracks progress over time and identifies areas where controls can be enhanced.

By embedding SEG sampling within the FACILEX® environment, AI ensures exposure monitoring is not just a compliance activity, but an integral part of safety decision-making.

Conclusion

The future of Process Safety Management lies in breaking down silos and connecting daily operations with strategic decision-making. By combining Industrial Hygiene SEG sampling, FACILEX® RBPS Suite, and AI-driven analysis, organizations can elevate exposure monitoring into a best practice that protects workers, strengthens compliance, and enhances leadership decision-making.In other words: from data to decisions, AI and FACILEX® ensure SEG sampling becomes a strategic advantage—not just a checkbox.

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Gateway Group

Gateway Consulting Group has been a leader in information management solutions for over 30 years, helping businesses navigate complex challenges with a blend of cutting-edge technology and expert consulting. By tailoring solutions to each client's needs, Gateway ensures efficiency, compliance, and streamlined business processes. With decades of experience, Gateway continues to deliver best-in-class strategies that optimize information management, combining innovative tools with a deep understanding of industry requirements.

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