Department of Chemical Engineering, KU Leuven, Process Safety Engineering,

Statistics for Safety Engineers (B-KUL-H08O3A)

Questions Q01, Q02 and Q03

• Confidentiality of data:
o Data for all cases are only for usage during this course,
o They may not be shared outside this course.
• Data are based upon.
o Real situations and measurements,
o But manipulated afterwards to serve this course.
o Hence: they do not reflect any real situation
Figure 1: Confidentiality and realistic data.

This document will get additional information during the progress of the course (answers at the
beginning of lessons 2 and 3)

Contents
1 Process description ......................................................................................................................... 3
1.1 Arrival at the waste treatment company ............................................................................... 3
1.2 Check on conformity by the laboratory ................................................................................. 3
1.3 Weighing of the truck............................................................................................................. 3
1.4 Unloading of the truck ........................................................................................................... 3
1.5 Weighing out .......................................................................................................................... 4
1.6 Leaving the treatment company ............................................................................................ 4
1.7 Business Process Map ............................................................................................................ 4
2 SIPOC............................................................................................................................................... 4
2.1 At level of complete process .................................................................................................. 4
2.2 At level of swim lanes within process .................................................................................... 5
3 Voice of the Customer .................................................................................................................... 5
4 CTQ’s ............................................................................................................................................... 6
5 Potential problems, within the process? ........................................................................................ 6
6 Questions ........................................................................................................................................ 6
6.1 Q01: Execute a risk assessment, using a fishbone ................................................................. 6
6.2 Q02: Elaborate the risk assessment, using a C&E and – if necessary – an FMEA .................. 6
6.3 Q03: Execute a statistical analyses on the “real situation” and verify your risk assessment 6

Confidential-do not share outside course – these are no realistic data Page 1 of 6
Department of Chemical Engineering, KU Leuven, Process Safety Engineering,
Statistics for Safety Engineers (B-KUL-H08O3A)

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Department of Chemical Engineering, KU Leuven, Process Safety Engineering,
Statistics for Safety Engineers (B-KUL-H08O3A)
1 Process description!

1.1 Arrival at the waste treatment company

The process deals with the delivery of waste on a Waste Treatment site.

Immediately after arrival of the truck, the truck driver hands over information to the guard, which
controls the information.

This information covers:

1. CMR documents: Legal documents, necessary to get allowance to drive on the road with this
product.
2. WIP: Waste Identity Passport: A description of the waste, delivered, referring to amongst
others the so-called EWC code, the European Waste Code

In case the documents are not ok, the guard asks the driver to contact the customer, to deliver the
correct documentation. The unloading is NOT allowed.

Iin case the documents art ok, the guard asks the truck driver to go to the acceptance laboratory. He
hands over a map with the ground plan of the site, indicating acceptance laboratory, weighing bridge,
and unloading areas. He also hands over a unique badge, allowing to open the different gates to the
unloading areas.

1.2 Check on conformity by the laboratory.

In case the documents are ok, the waste content is controlled by the laboratory on conformity with
the WIP and the agreement of the waste treatment company.

There are some possibilities:

1. The WIP is conform with the waste on the truck, the truck may go to the unloading area.
2. The WIP is not conform to the waste on the truck, but the EWC can legally be accepted by the
waste treatment company.
a. The customer is contacted, the deviation is discussed, and a new price is agreed
between the customer and the waste treatment company. The waste truck may go to
the unloading area.
b. The customer is contacted, the deviation is discussed, and a new price cannot be
agreed between the customer and the waste treatment company. The waste truck
leaves the area.
3. The WIP is not conform to the waste on the truck, and the EWC cannot legally be accepted by
the waste treatment company.
a. The customer is contacted, the deviation is discussed between the customer and the
waste treatment company. The waste truck leaves the area.

1.3 Weighing of the truck

In case the truck is allowed to unload, the laboratory people ask the truck driver to go to the
weighing area, badge, weigh and drive along to the unloading area.

1.4 Unloading of the truck

After weighing in, the truck drives to one of the unloading areas, as explained by the laboratory. At
that point, he opens the unloading gate.

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Department of Chemical Engineering, KU Leuven, Process Safety Engineering,
Statistics for Safety Engineers (B-KUL-H08O3A)
The operator checks the documents and decides whether to allow the unloading.

During unloading, the operator regularly checks on “hidden non-conformities”. If any, he stops the
unloading and repeats the actions, comparable to the actions by the guard at the entrance gate.

After unloading, the truck is allowed to go back to the weighing area.

1.5 Weighing out

The truck weighs out. The delivered amount is calculated.

1.6 Leaving the treatment company

The truck is allowed to leave the treatment company.

1.7 Business Process Map

Delivery
Customer

Waste to deliver No End

Haulier

At Waste
Treatment plant
Guard

Doc OK? No Contact customer Agreement? Yes New conditions

Yes No
Labo

Check waste Waste OK

Weighing

In In
unloading

Unload Waste OK

Figure 2: Business Process Map

2 SIPOC

Please certainly check this SIPOC’s on their correctness!

2.1 At level of complete process

S I P O C
Haulier e-CMR Acknowledged e- Haulier
CMR
Customer WIP Weight In Weighing
Weight out Weighing

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Department of Chemical Engineering, KU Leuven, Process Safety Engineering,
Statistics for Safety Engineers (B-KUL-H08O3A)
2.2 At level of swim lanes within process

S I P O C
Customer WIP
Haulier 1. e-CMR Haulier to guard 1. Acknowledged Haulier
2. Badge e-CMR.
2. Ok for
progress.
3. Badge
Guard 1. Checked Guard to Labo 1. WIP Labo
and OK
e-CMR
Guard 1. Badge Labo to 1. Weighing In Finance
weighing
Haulier 1. WIP Weighing to 1. Waste Waste
unloading treatment
company
Unloading to 1. Weight out Finance
weighing

3 Voice of the Customer

1. Customer
a. Wants the waste to be accepted, at the foreseen price and date.
b. Wants the analyses to be done in conformity with the highest standards.
2. Haulier
a. Wants to unload as fast as possible.
3. Laboratory
a. Wants the waste to be in conformity with the agreements.
i. For financial reasons
ii. For safety reasons
iii. For environmental reasons
b. Wants to work as fast as possible, as there is a lot of trucks to be sampled each day.
c. Want a high accuracy, to serve the customer as good as possible.
4. Guard
a. Wants as less problems with hauliers, customers, and laboratory, as possible.
b. Wants as less paperwork as possible.
c. Wants a fast progress, as there are many trucks each day.
5. Production
a. Wants only to conform waste.
b. Does not want to detect a non-conformity while unloading.
c. Wants to work as fast as possible, as there are many trucks each day.
6. Finance
a. Wants exact weights per truck, as soon as possible after weighing out.
b. Require the highest accuracy in weight.
c. Want as less nonconformities as possible, as this brings a lot of extra work.
d. Wants the highest throughput of waste, thus as much trucks as possible.
e. In case of non-conformity, wants the highest accuracy in the kind of non-conformity
and the correct price, which needs to be acknowledged in written by the customer.

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Department of Chemical Engineering, KU Leuven, Process Safety Engineering,
Statistics for Safety Engineers (B-KUL-H08O3A)
7. Legal
a. Only allows to accept EWC codes in conformity with the permit.
b. Wants a thorough check on each e-CMR, to avoid infringements during road-
transport.
8. Safety
a. Wants the PPE prescribed are in line with the delivered waste characteristics.
b. Wants as less non-conformities as possible, as this might induce manual intervention.

4 CTQ’s

The engineering department did not formulate CTQ’s based upon the VoC. Please foresee your own
CTQ’s based upon the VoC above.

5 Potential problems, within the process?

During this process, a lot of problems can potentially happen. One can e.g. think about wrong
documents, a non 100% analyses, the truck driver going to the wrong unloading area, etc.

We do not have an insight at this moment of what could happen.

6 Questions

6.1 Q01: Execute a risk assessment, using a fishbone.

Assume that you are developing a new process, which is not yet existing. You got the process
description. What are the potential things that can go wrong.

Therefore:

1. Formulate CTQ’s
2. Create a fishbone for the CTQ’s, to find the potential causes (X’s)

6.2 Q02: Elaborate the risk assessment, using a C&E and – if necessary – an FMEA

Based upon Q01 answers, you have an insight in the potential “X’s” that can lead to an unwanted
situation. As we cannot deal with all of them and because they are not all of equal importance, we
want to reduce the number of X’s.

Therefore:

1. Execute a C&E matrix.

2. Decide on whether you need an FMEA. If yes, execute the FMEA.

6.3 Q03: Execute a statistical analysis on the “real situation” and verify your risk assessment.

Situation: We are 1 year after the successful implementation of the process, mentioned above. There
is 1 year of data available. We now want to know whether our risk assessment was good enough or
we must add some additional risk mitigating actions.

Therefore:

1. Analyse the data of 1 year.

2. Check what went wrong, where we did not foresee the risks well enough.
3. Eventually propose mitigating actions.

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