Process Safety Management
Overview
This foundational service ensures that companies handling chemicals, combustible materials, pressurized systems, or flammable substances operate under a structured process safety system that reduces risks of catastrophic events.
Our Competitive Edge
PX Consulting adapts global best practices to Indian MSME contexts. We don’t just copy-paste frameworks—we translate them into your industrial reality, accounting for budget, manpower, and scale.
Our Solutions
- PSM System Design & Implementation: Developing a tailored PSM program with 14 elements aligned to OSHA and CCPS models.
- Process Lifecycle Risk Integration: Embedding risk controls into procurement, design, operations, maintenance, and change management.
- Mechanical Integrity & Reliability Programs: Assessing and maintaining critical equipment to prevent failure or loss of containment.
- Incident Investigation & Root Cause Analysis (RCA): Setting up systems for incident reporting, RCA, and learning implementation.
- Regulatory Compliance & Audit Readiness: Preparing for inspections by authorities (e.g., Factory Inspector, PESO) with full documentation and training.
With PX Consulting’s Process Safety Management framework, companies gain peace of mind and operational stability by proactively managing technical safety risks.
Process Hazard Analyses
Overview
PHA is a structured approach to identifying and analyzing potential hazards associated with chemical processes or operations involving hazardous materials. It forms the backbone of effective risk-based decision-making.
Our Competitive Edge
We use globally accepted methodologies (HAZOP, What-If, FMEA, Bow-Tie, LOPA) and customize the depth and scope based on plant size, complexity, and risk potential. Our team ensures participation from plant personnel to build ownership.
Our Solutions
- HAZOP Study Facilitation
Conducting guided hazard and operability studies for new or existing processes. - Risk Ranking & Prioritization Matrix
Classifying risks based on severity, likelihood, and existing controls. - Corrective & Preventive Action Plans (CAPA)
Suggesting actionable, prioritized measures to mitigate high-risk scenarios. - PHA Documentation & Traceability Systems
Providing structured reports, action trackers, and decision records for audits and reviews. - Refresher PHAs for Plant Changes
Facilitating re-analysis during expansions, modifications, or new product/process introductions.
PX Consulting ensures your PHA isn’t just a compliance activity—it becomes a critical enabler of safe, informed, and strategic operations.
Emergency Preparedness & Response Management
Overview
Emergencies such as chemical leaks, fires, explosions, and natural disasters can cripple operations and endanger lives. Our emergency preparedness and response services build resilience into your organization’s safety fabric.
Our Competitive Edge
PX Consulting offers a 360-degree approach, from on-paper plans to full-scale mock drills. We coordinate with local authorities, fire departments, and hospitals to align your preparedness systems with real-world response dynamics.
Our Solutions
- Emergency Response Plan (ERP) Development: Drafting site-specific ERPs covering fire, chemical release, natural disasters, and sabotage risks.
- On-site and Off-site Emergency Drill Design & Execution: Planning and conducting realistic drills in collaboration with authorities and first responders.
- First Responder & ERT Training: Equipping internal teams with rescue, first-aid, fire-fighting, and communication skills.
- Communication & Evacuation Protocols: Designing alarm systems, PA announcements, muster points, and safe exit pathways.
- Incident Command System (ICS) Setup: Establishing an organized structure for managing emergencies with clear roles and escalation processes.
Emergency preparedness with PX Consulting ensures that your organization can act quickly, decisively, and effectively when every second counts.
Workplace Safety Management
Overview
Workplace safety includes physical, behavioral, and ergonomic dimensions of employee well-being. This service supports companies in making the workplace not only accident-free but also psychologically and operationally safe.
Our Competitive Edge
We integrate workplace safety with HR, operations, and facilities management. Our focus on behavior-based safety (BBS), wellness, ergonomics, and visible leadership creates a lasting safety culture.
Our Solutions
- Workplace Risk Assessment & Control Implementation: Identifying hazards across workstations, access points, and shared areas.
- Safety Signage, PPE, and Zone Classification Systems: Standardizing visual and protective systems based on job roles and exposure levels.
Behavior-Based Safety (BBS) Programs: Driving safety ownership and reporting culture through employee engagement. - Ergonomics & Fatigue Management Programs: Reducing work-related musculoskeletal disorders and enhancing productivity.
- Occupational Health & Hygiene Assessments: Monitoring noise, air quality, lighting, and other health-impacting parameters.
PX Consulting transforms workplace safety from a checklist activity to a cultural advantage, making your people safer, healthier, and more productive.
Process Safety Culture Development
Overview
Beyond systems and audits, safety must live in the minds and behaviors of people. This service focuses on embedding a proactive safety mindset through leadership commitment, communication, and motivation.
Our Competitive Edge
We use global behavior change models, experiential workshops, and leadership coaching to help organizations move from reactive compliance to proactive prevention.
Our Solutions
- Leadership Safety Coaching & Goal Alignment
Coaching CXOs and Plant Heads to lead by example and embed safety in KPIs. - Safety Culture Assessments & Climate Surveys
Evaluating current mindsets and barriers to safe behavior at all levels. - Motivational Safety Campaigns & Recognition Programs
Designing reward systems and campaigns that celebrate safe behaviors. - Toolbox Talks & Peer Learning Modules
Creating conversation-driven learning platforms for frontline employees. - Visual Management & Safety Dashboards
Using signage, performance charts, and incident boards to drive awareness.
PX Consulting’s approach to building a process safety culture helps organizations turn safety into a shared value system—empowering teams to act, report, and lead with responsibility.
With PX Consulting as your Process Safety partner, your business gains more than just compliance—it secures operational continuity, employee trust, stakeholder confidence, and industry recognition. Our PSM programs are built for the scale, complexity, and aspirations of Indian MSMEs and mid-sized companies, delivering world-class safety, one process at a time.