+10
Manufacturing and processing sites
-40% Reduction in recurring safety incidents and unsafe conditions
Our client is a leading global agro-industrial manufacturer producing starches, proteins and functional ingredients for food, feed and industrial applications. With multiple production sites and a large operational workforce, the organization operates in a high-risk manufacturing environment. To strengthen safety performance and operational discipline, the company set out to embed behavior-based safety and robust work permit practices into daily operations, creating a safer and more consistent way of working across sites.
Industry: Food & Beverage
Service: People and Organization
Our Client
Our client is a leading global agro-industrial manufacturer producing starches, proteins and functional ingredients for food, feed and industrial applications. With multiple production sites and a large operational workforce, the organization operates in a high-risk manufacturing environment. To strengthen safety performance and operational discipline, the company set out to embed behavior-based safety and robust work permit practices into daily operations, creating a safer and more consistent way of working across sites.
+3K
Employees across operations and maintenance
24/7
Continuous production environment
The Challenge
The client was facing recurring behavioral safety incidents and unsafe conditions across two production sites. While formal safety protocols were in place, compliance was inconsistent and the work permit process lacked structure, ownership, and follow-up.
Limited control over contractors and technicians, particularly during maintenance stops and turnarounds, increased operational risk. The existing work permit system was unstable and largely administrative, with insufficient connection to on-site behavior and accountability.
In addition, unclear consequence management and inconsistent leadership engagement reduced the effectiveness of safety governance, resulting in safety procedures that were regularly not adhered to in practice.
The organization needed a more structured, behavior-driven safety framework that embedded accountability directly into daily operations and the work permit process.
Real Results Achieved Together
The initiative delivered a step-change in safety performance by strengthening behavioral ownership, improving process discipline, and embedding safety more firmly into daily operations.
+25%
Improvement in safe behavioral practices on site
+30%
Increase in compliance with standardized work permit processes
-40%
Reduction in recurring safety incidents and unsafe conditions
+100%
Clarity in safety roles, responsibilities, and follow-up across maintenance teams
Transformation Impact
- Designed and implemented a strengthened Behavioral-Based Safety framework integrated with the work permit process
- Increased safe behavior compliance and accountability across maintenance and leadership teams
- Standardized and stabilized the work permit process, improving consistency and follow-up
- Enhanced incident reporting, resolution speed, and cross-team safety awareness
Our Approach
- Implemented a behavior-based safety approach focused on on-site execution and leadership ownership
- Standardized and strengthened the work permit process to improve consistency and control
- Identified and addressed critical behavioral risk moments during daily operations and maintenance
- Embedded safety into daily management routines through co-creation, training, and clear accountability
Related Services
People and Organization
Workforce transformation, leadership development, and structure optimization. Learn more about our People & Organization consulting services.
Ready to Strengthen Safety Performance Across Your Operations?
- Reduce unsafe behaviors and increase compliance through a pragmatic Behavior-Based Safety approach
- Regain control over contractor and maintenance activities with a streamlined work permit process
- Build a safety culture that improves accountability, reporting, and long-term operational reliability
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