HFE in New Facilities Projects - PDO

Human Factors Engineering (HFE)
in New Facilities Projects
July 2003
Policy and strategic objectives
Organisation, responsibilities
resources, standards, documents
Hazards and Effects Management
Planning and procedures
Implementation
Audit
Management review
Health, Safety and Environment HSE
Shell Health, Safety and Environment Panel
Corrective action
Monitoring
Corrective action and improvement
Corrective action and improvement
b

Human Factors Engineering (HFE)
in New Facilities Projects
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in contexts where reference is made to the companies of the Royal Dutch/Shell Group in general. These
expressions are also used where no useful purpose is served by identifying the particular company or
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arrangements in existence with companies of the Royal Dutch/Shell Group; it is issued for the guidance of
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All rights reserved.
July 2003
Human Factors Engineering (HFE) in New Facilities Projects, Issue 2.0, July 2003
d

Document History
Date Issue Reason for change Author Approval Signature
December 1995 1.0 First Issue HSE
July 2003 2.0 Second Issue HE/2
The printed version of this document is the controlled version. It is also available on the
PXE Website: http://sww.shell.com/hse/group/hse/hse_publications/publications.htm
Superseded issues of this document should be destroyed.
e Human Factors Engineering (HFE) in New Facilities Projects, Issue 2.0, July 2003

Table of Contents
Table of Contents
1 Purpose 1
2 Scope and Applicability 2
3 Group Standard 3
4 Management System 4
4.1 Conduct a gap analysis on the existing project management procedure. 4
4.2 Update project management procedures and assure competence. 4
4.3 Implementation of Procedure HE.03.007 5
5 References 6
Human Factors Engineering (HFE) in New Facilities Projects, Issue 2.0, July 2003
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1
Purpose
Purpose
There is signifi cant evidence that systems which adhere to the “human-centred design” philosophy
during early development often result in increased productivity, enhanced quality of work, safer
and more healthy working conditions, a reduction in support and training costs, and improved user
satisfaction (ref. 1). Although the human-machine interface in process industry projects has always
been considered to be an integral part of a sound engineering design, many misfi ts in operability,
maintainability, system reliability and product design are still experienced during the operational
phase.
HFE is an approach to system design focused on usability to enhance user effectiveness, effi ciency,
as well as safe and healthy working conditions. Achieving a “right fi rst time” design requires the
integration of specifi c activities in the early development phases of the project design process.
The objective of this Guide is to assist managers responsible for preparation and execution of
“new facilities projects” (see Section 4 of this guide) to comply with the MHMS for Human Factors
Engineering (ref. 2).
Human Factors Engineering (HFE) in New Facilities Projects, Issue 2.0, July 2003 1

2
Scope and Applicability
Scope and Applicability
The Standard for HFE shall be applied to all ‘new facilities projects’ i.e.:
• New plants/facilities (on - and offshore);
• Revamp of an existing plant/facility 1 ;
• Buildings and workstations design (e.g. retail stations, central control rooms, offi ces, workshops,
laboratories);
• IT software/hardware, instrumentation.
The Guide is supported by a detailed Procedure which is described in the document HE 03.007
“Human Factors Engineering Project Design Procedure” (ref. 3), which is now being converted into
a Design and Engineering Practice (DEP) (ref. 4).
1 Unless there is no change to the work system (e.g. like-for-like change out, and no benefi ts from
design improvements can be justifi ed).
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3
Group Standards
Group Standards
The Group Minimum Health Management Standard states:
Human factors engineering principles are to be considered and applied during the early design
stage of new facilities projects where design can have a critical impact on equipment usability
and user safety or health.
The achievement criteria for this Standard are:
1. All new facilities projects are reviewed for minimum human factors engineering requirements.
2. Where the screening indicates that HFE input is necessary, the location or business applies the
correct processes, tools and competencies at the correct stages of the project as referred to in
the HFE Yellow Guide.
3. The recommendations have been discussed with management and action parties and target
dates agreed.
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4
4.1
4.2
Management System
Management System
In order to prepare for the execution of the MHMS on a project, the following key steps are
recommended:
Conduct a Gap Analysis on the Existing Project Management Procedure
To be effective, it is necessary that requirements for HFE - (in terms of activities, their deliverables
and timing) - are suitably embedded within an organisation’s project management procedure.
Therefore, the existing project management documentation should be compared with the
requirements of the HFE Procedure (ref. 3 / 4) to identify gaps.
Update Project Management Procedures and Assure Competence
The results from the gap analysis should form the basis for a plan to integrate HFE requirements
into the current procedures. The following activities should be undertaken:
a) Embed the Procedure’s requirements (ref. 3 / 4) into the Project Management procedure
documents.
Activities, deliverables and their timing should be stated, and support documents added
(e.g. HFE DEPs and other relevant HFE international or local standards) into the project
procedure.
b) Ensure PT members who will be responsible for carrying out HFE activities on a project,
are identifi ed.
c) Ensure competence of PT members.
PT members will be required to meet competence standards as defi ned in ref. 3 / 4, and be
trained as required, in order to be able to effectively execute their responsibilities within the
updated Project Management procedure.
d) Identify need for HFE specialist.
Once a project is triggered, and the review by the PT identifi es the need for a specialist Human
Factors Engineering input for specifi c activities, then suitable resources should be identifi ed
(ref. 3 / 4).
4 Human Factors Engineering (HFE) in New Facilities Projects, Issue 2.0, July 2003

4.3
Management System
Implementation of Procedure HE.03.007
a) For both large and small projects the nominated Project Team (PT) shall execute the fi rst step of
the Procedure (HE.03.007) i.e. a screening of the project to identify whether a HFE scope of work
would benefi t the project or not.
b) The PT would typically include the Project Manager, Process Engineer and Operations/
Maintenance representatives. It is envisaged that depending on the complexity and size of a
project this screening of the project will require anything from 30 minutes to 2 hours using
competent team members.
c) If the review does identify the value in applying HFE on the project, then the remaining steps in
the Procedure shall be followed.
d) If no HFE scope is deemed necessary, a short audit trail on the rationale for this is required for
close out and audit purposes.
Human Factors Engineering (HFE) in New Facilities Projects, Issue 2.0, July 2003 5

6
References
References
1. ISO 6385, Ergonomic principles in the design of work systems & ISO 13407, Human Centred
design processes for interactive systems
[These ISO Standards describe the basic approach to Human Centred Design Processes and
underpin the requirements within the MHMS for HFE]
2. Group Minimum Health Management Standards, June 2001
[Contains all the MHMS including the Standard on HFE]
3. HE03.007 “Human Factors Engineering Project Design Procedure”
[This Procedure contains the detailed steps to be followed in meeting the MHMS on HFE.
It is currently being made into a DEP – see new full reference below]
4. DEP 30.00.60.10 Human Factors Engineering Project Design Procedure
[In preparation; it contains Ref. 3]
5. OG Project Guide 1A: Health, Safety, Environment and Sustainable Development Assurance for
Capital Projects.
[This OG Project guide, used for all OG Projects, contains the essential activities and deliverables
as described in Ref 3 and 4 above as part of an overall project execution procedure. OG has
through this Project Guide integrated MHMS HFE requirements into their project quality
management procedures]
6 Human Factors Engineering (HFE) in New Facilities Projects, Issue 2.0, July 2003

H S & E Publications Issued under the Auspices of the Shell HSE Committee/HSE Advisers Panel
Royal Dutch/Shell Group Health, Safety and the Environment Commitment and Policy (1997)
Royal Dutch/Shell Group Procedure for HSE Management Systems (1997)
Group HSE Management System (2002)
HSE Management System, Integrating HSE into the Business (1994) only elec.
Group Health, Safety and Environmental (HSE) Auditing Guidelines (2001)
Group HSE Performance Monitoring and Reporting (2002) only elec.
HSE Management Systems Management Information (1998)
HSE Management Systems Incorporating Health Risks in an HSE Management System and HSE Cases (1998)
HSE Management Systems Incorporating Environmental Risks in an HSE Management System and in HSE Cases (1999)
Occupational Health Guidelines
Asbestos (1986)
Chemical Hazards: Health Risk Assessment and Exposure Evaluation (1995)
Fitness to Work – Management Process (2003)
Health Guidelines for Catering (1995)
Health Risk Assessment (2001)
Human Factors Engineering (HFE) in New Facilities Projects (2003)
An Introduction to Health Risk Assessment: Training Package (2002), available through Open University,
see: http://sww-openuniversity.shell.com/scripts/dlmisapi.dll/GET?fi le=frameset.jsm&rshost=sww-openuniversity.shell.com&rsport=1564
Go to e-learning and then HSE and S
Management Guide to Thermal Stress (1991)
Management Guidelines for Hearing Conservation (1991)
Man Made Vitreous Fibres (2002)
Medical Emergency Guidelines for Management (2001)
Noise Guide (1991)
Personal Protective Equipment Guide (1989)
Repetitive Strain Injury (RSI) in the Offi ce Environment (2002)
Risk Assessment Matrix (1999)
The Use of Contact Lenses in Industry (1984) leafl et
Safety Guidelines
Company-Organised or Supported Social Events - Safety Considerations (1990) leafl et
Contractor Safety (1987)
Diving Operations Management Guidelines (1991)
Electrical Safety (1986)
Enhanced Safety Management (1985)
Enhanced Safety Management Checklist (1989)
Gas-freeing and Cleaning of Storage Tanks (2003)
Guidelines for Entry into Confi ned Spaces (1992)
Guidelines for Laboratory Safety (1989)
Hand Tools and Sparking Hazards (1982) leafl et
Hotel Fires, Plan for Survival (1988) leafl et
Hydrogen Sulphide (1986)
Incident Classifi cation, Investigation and Reporting (2002)
Ionising Radiation Safety Guide (1993)
Offi ce Safety (1987)
Oxygen - A Hazard (1982) leafl et
Permits to Work Systems (2003)
Personal Protection of Helicopter Passengers in the Event of Ditching (1995)
Road Transport Safety Management System Guidelines for Heavy Goods Vehicles (1995)
Safety Features of Light Vehicles and Mini Buses (1997)
Safety Signs and Colour Coding (1981)
Scaffolding Safety (1987)
Seat Belts (1989)
Static Electricity, Technical and Safety Aspects (1988)
The Secondary Use of Containers (1978) leafl et
Tripod-BETA (Incident Analysis EP 95-0321, to be ordered through EP)
Unsafe Act Auditing (1987)
The Use of Small Marine Craft by Group Companies (1992)
Welding and Cutting (1976)
Environmental Guidelines
Guide for the Risk-Based Management of Potentially Contaminated Land (2000)
Recommendations for Alternatives to Fire Fighting Halons (1994)
Safe Handling and Disposal of PCBs (1985)
Technical Guidance for Environmental Assessment (2000)
Volatile Organic Compounds (1996)
Waste Management Guide (1996)
These publications can be ordered from SI The Hague;
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H S & E Publications Issued under the Auspices of the Shell HSE Committee/HSE Advisers Panel
July 2003

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Human Factors Engineering (HFE) in New Facilities Projects, Issue 2.0, July 2003