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How a Safety SOP Fix Prevented 55 QNs at a Global Chemicals Site
Safety and logistics are often treated separately — until they collide at the gate. At a European chemicals site, Zyra Consulting uncovered how missing anti-slip mats at truck unloading bays were not just a safety risk, but a barrier to logistics flow and EH&S compliance.
The Challenge: Over 55 Quality Notifications (QNs) had been issued due to safety non-conformities. Some shipments were rejected at the gate because unloading areas lacked anti-slip mats — a serious risk under wet conditions.
Our Approach: Using the Six Sigma DMAIC methodology, Zyra:
- Mapped the root cause across EH&S, Logistics, and Procurement
- Conducted on-site audits and SAP field analysis
- Developed a direct supply model for mat provisioning at gates
- Rolled out a location-wide safety SOP
The Result:
- 100% gate compliance within 3 months
- €89,000 in cost savings through bulk procurement and rejection avoidance
- Rework and QNs dropped to near-zero
What Made It Work: We didn’t just suggest a fix — we embedded the solution into SAP routing, EH&S governance, and procurement flow. A simple mat became a process breakthrough.