Maintenance Management Review In The Safety Management System Of A Major Hazard Plant. Mario Tucci, Ph. D., University of Florence Irene Cappelli, Ph.D., University of Florence Francesca Tocchi, University of Florence Corso Piazzini, University of Florence Key Words: maintenance management, major hazard plant, maintenance policy, system review SUMMARY & CONCLUSIONS The paper presents a case study: the review of the maintenance management system realized in a major hazard plant. The review verified the actual application of the management system and assessed the system implementation as regard the real needs of the plant itself. In fact, only an application closed to the plant requirements can allow law observance, management optimization and economic results as well. In particular, the management system was valued taking into account its design and its implementation. The analysis was carried out in a chemical plant and the study was realized in the following three steps: o Conducted a preliminary system review on the basis of an RCM (Reliability Centered Maintenance) model; o Conducted a sample data collection effort concerning a Computerized Maintenance Management System (CMMS), using by interviewing personnel and reviewing information contained in safety and management reports; o Analyzed data in order to identify data issues within the maintenance management system and to evaluate possible maintenance policies. The study prepared three main findings which will be implemented into the plant system. To date, (1) the plant reliability analyses have been integrated by data obtained both from database and interviews, and according to the upgrading operations carried on the original system during the years; (2) a new equipment and component codification have been proposed in order to identify univocally the components of the plant; and (3) new possible maintenance policies have been identified in order to reduce costs and new possible economic investments have been evaluated. 1. INTRODUCTION Italian laws (D.Lgs 334/99) rule the field of major hazards in Italy, according to the European Seveso Bis directive, which aims to reach two main results: accident prevention and consequence reduction. In order to obtain those outcomes, the law imposes the application of a Safety Management System (SMS), which serves as a consistent tool to prevent major accidents. In a safety management system, the conduct of maintenance has the predominant role, such that Maintenance Management (MM) is named by the normative to gain a correct and effective implementation of an SMS. In this meaning, the integration of the MM into safety management system is the most effective way to reach all goals established by the Seveso Bis directive. Since the 1990's, organizations have been required to comply with the law and have therefore, been re-organizing their safety system programs. Even if re-organization effort could have been seized as an opportunity to adopt an integrated management system, companies often were not able to meet that objective in a systematic way, resulting in a circumstance where the MM meets the requirements of the law, but does not serve as a useful and understood tool. In fact, the optimum outcome for the adoption of an integrated management system, based on a strong maintenance component), is the achievement of both economic improvements and the changing of possible expenses into sources of financial resources for the operating plants as well. 1.1 Study Object In this context the study aim was to show that a management system is not only a tool to answer to the normative needs, but also to satisfy technical and economical requirements. To reach these results, a real SMS implemented by a major hazard plant was analyzed, focalizing on the management system. The investigation concerned: o the actual application and using of the management system, o the real relation of management system to the actual needs of the plant, o the efficacy of feedback process. Hypothesizing possible improvements on the MM, the analysis wanted to show how economic, safety and environmental requirements can be satisfied as well. In fact, the integration and changes identified by the study seem able to make the maintenance management system more efficacy both for the normative requests both in term of productivity and competitiveness. 2. THE ANALYSIS STEPS The analysis was carried out in a chemical plant and crosses through the following steps: 1-4244-0008-2/06/$20.00 (C) 2006 IEEE 563