Case Study: Achieving 412 Days Zero LTI in a 2 MTPA Integrated Steel Facility
How an integrated steel manufacturer deployed beSafe PTW & LOTO modules to eliminate high-risk work incidents across 4 plant units.
Integrated steel facilities present complex operational hazards including molten metal handling, blast furnace gas (CO) exposure, overhead crane lifting, and multi-level contractor activities.
The Challenge Prior to deployment, the facility relied on paper permit books and physical log sheets across 4 operating units, resulting in: - Unchecked SIMOPS conflicts during shutdown maintenance. - Inconsistent energy isolation verification (LOTO try-out tests). - Delayed CAPA closure for field hazard observations.
The Solution & Deployment The plant digitised its permit-to-work workflow using the **beSafe EHS Platform**: - Installed QR codes at all 180 substation breakers and isolation valves for mobile LOTO validation. - Enforced mandatory digital double-signoff (Issuer + Senior EHS Officer) prior to hot work authorization. - Automated SIMOPS conflict checks preventing simultaneous permits in adjacent gas-hazard zones.
Quantifiable Results - **412 Consecutive Days Zero LTI** achieved across 3,500 employees and contractors. - **-92% Reduction** in permit approval waiting time. - **100% Audit Readiness** during statutory Factory Inspectorate reviews.
Related Resources & Guides
Navigating the OSH Code 2020: Statutory EHS Audit Checklist for Plant Managers
A practical guide to the Occupational Safety, Health and Working Conditions Code 2020 and its impact on plant compliance, safety officer duties, and statutory inspections.
GuidesStandard Operating Guide: Energy Isolation (LOTO) & Permit Control
Step-by-step technical guide for establishing a Zero Energy State before high-risk mechanical or electrical maintenance.
DownloadsDownload: Plant-Wide HIRA 5x5 Risk Assessment Matrix Template (Excel & PDF)
Download our editable 5x5 Hazard Identification and Risk Assessment (HIRA) template compliant with IS 14489 audit standards.
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