A “Complete Solution” for risk-based process safety management, as defined in the Center for Chemical Process Safety (CCPS) guidelines incorporates four foundation blocks:
- Commit to Process Safety
- Understand Hazards and Risks
- Manage Risks
- Learn from Experience
These foundation blocks support the twenty pillars of Risk-Based Process Safety (RBPS). The Corrective Action Request process is integral to several of the pillars of process safety.
What is a Corrective Action Request?
A Corrective Action Request (CAR) is a structured process for identifying, documenting, and resolving safety issues that arise from incidents, near misses, audits, inspections, and risk assessments. It ensures that problems are not just identified but also addressed in a systematic way, preventing recurrence and driving continuous improvement.
How the CAR Process Supports RBPS
The CAR process directly aligns with several key elements of Risk-Based Process Safety, including:
1. Incident Investigation
When an incident or near miss occurs, an investigation identifies the root cause. A CAR is then issued to track corrective actions that eliminate hazards and prevent recurrence. Without this follow-up, organizations risk repeating the same mistakes.
2. Hazard Identification and Risk Assessment
Risk assessments help uncover weaknesses in processes, equipment, or procedures. When a deficiency is identified, a CAR ensures that necessary safety improvements are documented, assigned, and completed.
3. Management of Change (MOC)
Whenever changes occur—such as modifications to equipment, processes, or personnel—new risks may emerge. The CAR process helps ensure that these risks are evaluated and mitigated before they lead to unsafe conditions.
4. Operating Procedures
Clear and up-to-date operating procedures are crucial for safe operations. When gaps or inconsistencies are found, CARs prompt revisions and improvements, ensuring that employees have accurate and reliable guidance.
5. Auditing and Performance Measurement
Routine audits often uncover noncompliance or weaknesses in safety practices. The CAR process ensures that findings are tracked, corrective actions are assigned, and improvements are verified—ensuring compliance with safety standards.
6. Continuous Improvement
Safety is not a one-time effort—it requires ongoing evaluation and enhancement. By systematically addressing issues through the CAR process, organizations create a culture of continuous improvement, reinforcing safety as a core value.
Final Thoughts
For a PSM-covered facility, small corrective actions today can prevent major incidents tomorrow. By making CARs a fundamental part of their safety culture, organization can reduce risks, enhance compliance, and continuously improve process safety performance.
