Development and Implementation of a Process Safety Management Framework for a Fertiliser Manufacturer
Executive Summary:
Challenge: New 2022 OHSAct MHI regulations required compliance and stronger process safety culture at a major fertiliser facility.
Approach
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Diagnostic review of process safety maturity, compliance gaps, and leadership vision.
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Designed and implemented a bespoke PSM framework across 14 elements.
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Developed Quantitative Risk Assessment, PSM Standard, Major Incident Prevention Policy, and Safety Report.
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Embedded cultural change by aligning leadership vision with operational execution.
Outcome
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Regulatory compliance achieved.
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Tailored systems and standards embedded across operations.
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Enhanced internal capability through co-development, training, and knowledge transfer.
- Sustainable safety culture established, moving beyond compliance to shared ownership of safety.
Case Study
AFRISHE was engaged to develop and implement a comprehensive Process Safety Management (PSM) framework for a major South African fertiliser manufacturing facility, in alignment with updated 2022 OHSAct MHI Regulations and current global best practices. Over a 24-month period, AFRISHE led this engagement through a multidisciplinary project team consisting of senior and principal consultants (SMEs) all operating across focused technical workstreams (14 PSM Elements). The project scope included compliance with new regulatory requirements, such as the development of Quantitative Risk Assessment (SANS 1461), a Process Safety Management Standard, Major Incident Prevention Policy (MIPP), and Safety Report.
The project commenced with a diagnostic phase designed to assess the facility’s current state of process safety maturity, regulatory compliance, and operational practices. AFRISHE engaged directly with the client’s board and leadership teams to understand their strategic vision for safety, PSM, and broader operational excellence. These conversations were instrumental in shaping a bespoke programme that balanced technical compliance with transformative cultural change. Rather than applying a generic framework, AFRISHE developed an implementation approach that reflected the client’s aspirations, ensuring that process safety was not only embedded as a system but championed as a shared value across the organisation. This alignment between leadership vision and on-the-ground execution laid the foundation for a sustainable and empowered safety culture.
AFRISHE provided not only strategic leadership and oversight throughout the project lifecycle but also deep technical expertise across all key pillars of process safety. The consultancy ensured that technical deliverables were not merely implemented in isolation but co-developed with client teams to foster long-term sustainability. Subject matter experts from AFRISHE led the creation of tailored process safety standards and procedures, co-facilitated critical implementation phases, and delivered targeted capacity-building workshops aligned to the client’s operational context. This collaborative approach enabled joint ownership of safety outcomes, strengthened the competency of internal teams, and embedded regulatory understanding within day-to-day operations. Regular technical reviews, integrated stakeholder sessions, and structured feedback loops ensured continuous alignment with the client’s evolving needs. By prioritising knowledge transfer and operational empowerment, AFRISHE ensured the project delivered lasting value beyond compliance, equipping the client with the tools, systems, and confidence to independently sustain process safety excellence.
