Ensuring safety at a pesticide manufacturing plant through effective maintenance

The Hungarian pesticide manufacturing company on which this case study is based identified that effective equipment maintenance is a key component of safe plant operation. A new, more efficient system for maintenance management, involving regular equipment monitoring and the use of customised software to record and track faults and repairs, has been implemented. Regular audits and bonuses for accurately reporting non-compliance have been used as incentives among employees and to raise awareness of the importance of effective maintenance. The company has focused particularly on subcontractors, establishing clearly documented regulations for working conditions, work permitting and the supervision of contractors. Management commitment to effective maintenance and good communication with employees and subcontractors have been crucial to the success of this new system and in the development of the company’s safety culture.