Modernizing PSM for Safer Chemical Handling

The Challenge: Outdated SOPs and Chemical Labeling Created PSM Risk

A resin manufacturing facility specializing in specialty polymers was flagged during an internal audit for incomplete SOPs, outdated safety data sheets (SDS), and poor chemical labeling practices—leaving the company vulnerable ahead of a scheduled OSHA Process Safety Management (PSM) audit and Tier II EPA reporting deadline.

The existing safety system lacked structure and consistency, creating operational confusion and documentation gaps across shift teams and contractor interfaces.

Key issues:

Inconsistent SOP formats and outdated revision history
SDS binders missing for multiple chemicals
Employees unaware of emergency response and hazard communication processes
No formal Tier II preparation procedures or audit logs

Chemical Industry Case Study: Modernizing PSM for Safer Chemical Handling

Our Solution: Comprehensive Process Safety Modernization

Rewrote all critical SOPs

to standardize layout, language, and control measures across processes.

Digitized SDS database

with 100% inventory coverage and QR code access per station.

Implemented a chemical labeling system

aligned with GHS standards and trained staff on container management.

Delivered PSM-specific training

to all supervisors, operators, and maintenance teams.

Created a Tier II Reporting Toolkit

with chemical inventories, threshold planning data, and submission workflows.

Established internal audit checklists and a compliance calendar

to track progress and sustain improvements.

The Results: Audit Success and Long-Term Risk Mitigation

Achieved 98% compliance score in OSHA PSM audit

Tier II submission approved on first attempt

SDS program fully digitized and accessible

Employee confidence and reporting improved significantly

Eliminated OSHA fine risk for unaddressed chemical hazards

Client Feedback

Apt helped us move from reaction mode to leadership mode. Their PSM overhaul made us stronger, safer, and fully compliant.”— EHS Director, Resin Manufacturing Plant