Items (List) | McMillen Process Safety Management

What do we actually need help with?

That’s a common question and a great place to start.

Many of our clients come to us knowing something isn’t working, but not exactly sure what the root issue is. Maybe a recent audit exposed gaps. Maybe a PHA revalidation is overdue. Maybe your team is overwhelmed trying to maintain a bloated program that no one’s confident in. That’s where we come in.

Our Initial Consultation is designed to help you clarify what’s really going on, where the friction points are, and what kind of support will deliver the most impact. Whether it turns out to be focused training, program cleanup, audit prep, or help facilitating PHAs. We'll identify the priority areas and map a clear path forward.

You don’t need to have the answers before you call us. You just need to know you want Simple Results for Safer Ops. We’ll help with the rest.

How long does the process take, and will it disrupt our operations?

It depends on the scope but we design every engagement to move efficiently and minimize disruption to your day-to-day operations.

During our Initial Consultation, we’ll define your goals, timing, and any operational constraints (like turnarounds or shift schedules). From there, we develop a tailored plan in the Delivered Results Strategy phase that outlines expected duration, key milestones, and resource needs.

For example:
A single-unit PHA may take a few days, while a large multi-unit facility could span several weeks.
Program simplification or audit preparation may be phased over several months, with minimal disruption
to operations.
Training sessions can often be delivered remotely or during scheduled downtime.

We’re flexible in how we schedule our work—whether that means off-shift meetings, remote sessions, or working around production windows. Our focus is always the same: delivering value without unnecessary noise.

We respect your time, your team, and your process. And we never forget the goal, Simple Results for Safer Ops.

What information do you need from us before a project begins?

We follow a clear, structured process from, First Call to Final Results, so you know what to expect and what’s needed at each step.

Before we begin a project, we start with an Initial Consultation to understand your immediate need, the state of your current PSM systems, and your long-term vision. During that conversation, we’ll ask for key information to help us right-size our support, such as:

A general description of the issue or objective
Any relevant PSM documentation (PHAs, audit findings, MOC logs, procedures, etc.)
Site-specific factors like processes involved, staffing, or past incident history
Project constraints, target timelines, or shutdown schedules
Primary points of contact for coordination

From there, we move into the Delivered Results Strategy, where we define the scope, deliverables, and a practical plan tailored to your operation. If documentation is missing or your program is in early stages, that’s not a problem we meet you where you are and build from there.

The information you share upfront allows us to focus quickly and efficiently on what matters most, delivering Simple Results for Safer Ops.

Can you work remotely, or do you require site visits?

We do both as well as hybrid and we’ll recommend the approach that makes the most sense for your situation.

At McMillen Process Safety, we’re highly effective working remotely, especially for services like straightforward PHA facilitation, training, and program development. Remote support helps us keep timelines on track, reduce travel costs, and stay flexible when your team is spread across locations or operating with limited availability.

That said, some services benefit from boots on the ground. These include compliance audits, complex PHA studies, facility walkthroughs, field verification, and direct operations engagement. When an on-site presence adds value, we’re there.

Ultimately, we adapt to your needs, your timeline, and your team’s availability because real support means meeting you where you are. And no matter how we work, our focus stays the same: Simple Results for Safer Ops.

Do we really need a PSM consultant, or can we handle this in-house?

At McMillen Process Safety, we’re here to strengthen and supplement your team. Your facilities have smart, capable people in place, and OSHA's 1910.119 Process Safety Management regulation is complex, difficult to implement and maintain. Our role is to help you cut through the clutter, identify what actually matters, and deliver usable, right-sized solutions that keep your processes controlled and your people safe.

Whether you're facing a series of PHAs, coming up on your three audit rotation, or just require advanced training to improve your programs and support your existing team, we bring deep expertise, real-world experience, and a focus on results that work in your day-to-day operations, not just on paper.

What qualifications should a process safety consultant have?

A strong process safety consultant should bring more than just regulatory knowledge, they should bring real-world experience, practical judgment, and the ability to deliver results that actually work in your facility.

At a minimum, your consultant should have a deep understanding of OSHA 1910.119, industry best practices, and the ability to apply both to a wide range of operations. But that’s just the start. You also want someone who’s facilitated PHAs across industries, led compliance audits, and helped teams implement PSM systems that are usable, not just technically correct.

At McMillen Process Safety, our consultants combine decades of field experience across multiple industries with a relentless focus on simple, effective results. We’ve sat in your chair, we understand the operational pressures you face, and we know how to tailor solutions to your needs, not hand you a binder you’ll never use.

Our team has gone through rigorous training to earn credentials including Certified Process Safety Auditor (CPSA®), Certified PHA Practitioner (CPP®), and Project Management Professional (PMP®). Many of our consultants also hold Bachelor's degrees in Engineering and MBAs, providing both technical and strategic insight.

Are you available for ongoing support or just project-based work?

We offer both. McMillen Process Safety provides flexible engagement models, whether you need one-time support for a specific project or ongoing partnership to maintain and improve your PSM program over time.
For project-based work, we often support PHAs, audits, training, or program development efforts with a clear start and finish. But many clients also rely on us for longer-term support—especially when internal resources are stretched thin or they want to maintain consistency across multiple sites.

Our ongoing support can include:
PSM program coordination
Periodic training and PHA facilitation
Audit preparation and follow-up
General consultation on day-to-day PSM implementation

We act as an extension of your team—offering guidance, structure, and support without adding headcount. Whether it’s short-term or strategic, our role stays the same: deliver Simple Results for Safer Ops.

What systems have you worked with before?

Our team at McMillen Process Safety has experience working with a wide range of PSM-related systems and platforms because no two facilities manage their programs the same way. Whether you're running fully integrated digital tools or a patchwork of spreadsheets and paper binders, we've been there.

Systems we've supported or integrated with include:
- PSM & EHS Management Platforms including SAP and Enablon
- PHA and LOPA Software – Such as PHAWorks, PHAPro, LEADER, and custom spreadsheet-based systems
- Maintenance & Mechanical Integrity Systems like SAP PM and other CMMS tools
- Document Control and Training Platforms including SharePoint, OneDrive, Learning Management Systems (LMS), and industry-specific solutions
- Custom & Hybrid Systems. Many clients use tailored combinations of Excel, Access, or internal platforms. We help organize and optimize what you already have

Our goal is to help make the most of your current tools; refining processes, simplifying workflows, and ensuring everything connects to support efficient, safe, compliant operations. No matter the system, our focus remains the same: Simple Results for Safer Ops.

What industries do you specialize in?

At McMillen Process Safety, we specialize in industries where hazardous chemicals, complex systems, and regulatory oversight intersect, especially those covered under OSHA 1910.119.

Our core industries include:
- Oil & Gas. Focused on midstream and downstream operations with intense reliability and uptime pressures
- Pharmaceuticals. Supporting both batch and continuous manufacturing, where quality-driven processes must align with safety-critical systems
- Specialty Chemicals. High-variability, high-hazard environments that demand custom-fit programs and detailed hazard analysis
- Food & Beverage. Especially facilities using ammonia refrigeration, Clean-In-Place systems, or other hazardous substances

Our specialization isn't just in the industries, it’s in how we deliver. Every McMillen Process Safety consultant is trained to understand and ask the good questions to explore the unique risks and process demands of your operation. Whether you're running a multi-reactor batch process or a continuous distillation unit, our team knows how to tailor your hazard assessments, audit findings, and compliance programs to match the way you work.

We combine industry experience with deep technical knowledge and practical judgment to deliver Simple Results for Safer Ops, no matter your industry or process type.

What industries have you worked with?

McMillen Process Safety supports a wide range of industries where process safety is critical to both operations and compliance. Our consultants have worked across facilities of all sizes, from standalone manufacturing sites to large, multi-site enterprises.

Industries we’ve worked with include:
- Oil & Gas, including midstream and downstream operations
- Pharmaceuticals – Supporting batch and continuous operations
- Food & Beverage. Especially in facilities handling anhydrous ammonia, Clean-In-Place systems, and other hazardous chemicals
- Specialty Chemicals. High-mix, high-hazard environments requiring tailored PSM programs
- Legal & Insurance Firms. Supporting case investigations, expert witness services, and risk evaluation tied to industrial incidents

In addition to working directly with operating companies, we also partner with engineering firms, risk management consultants, and fellow PSM specialists to support their clients with focused expertise and practical deliverables.

Do you provide Mechanical Integrity program support?

Yes, McMillen Process Safety provides Mechanical Integrity (MI) program support focused on the programmatic and compliance side of MI, rather than deep technical engineering or inspection work.

Our role is to help ensure your MI system meets the intent of OSHA 1910.119 while remaining usable, sustainable, and aligned with your operations. That includes evaluating MI programs during audits, identifying gaps in procedures or documentation, clarifying roles and responsibilities, and helping integrate MI into your broader PSM framework.

We assist with:
- MI element audits and gap assessments
- Procedure development and standardization
- Training on MI-related responsibilities under PSM

We don’t perform inspections, develop equipment-specific inspection plans, or provide engineering calculations, however, we work alongside your internal resources or third-party specialists to ensure everything ties back to a strong, compliant program.

Our goal is simple: help you maintain an MI system that works, not one that’s overly complicated or disconnected from day-to-day reality. That’s how we deliver Simple Results for Safer Ops.

Can you train our team on PSM requirements?

Yes, we provide targeted, hands-on training designed to help your team understand and apply Process Safety Management requirements in real-world operations.

At McMillen Process Safety, our training goes beyond the regulations. We tailor each session to your team’s roles, your facility’s processes, and your current program maturity. Whether you need foundational training for operators, in-depth instruction for engineers and supervisors, or refresher courses ahead of an audit or inspection, we build sessions that are relevant, engaging, and immediately usable.

We cover all key elements of OSHA 1910.119, including MOC, PHA, compliance audits, incident investigation, mechanical integrity, and more. Always tying the material back to your actual processes and responsibilities. We offer general PSM awareness training, program development guidance, and PHA facilitation training, and we can customize sessions to meet your specific needs.

Our goal is to build internal confidence, improve implementation, and reduce reliance on external support over time.

Because when your people understand the why behind PSM—not just the what—you’re in a stronger position to sustain safer operations. That’s how we deliver Simple Results for Safer Ops.

Do you facilitate PHAs, HAZOPs, or LOPA studies?

Yes. Facilitating high-quality PHAs, HAZOPs, and LOPA studies is one of our core service offerings and one of the areas where McMillen Process Safety truly stands out.

Whether you're preparing for a new process, revalidating an existing one, or addressing findings from an audit or incident, our team brings the structure, experience, and focus needed to run effective studies. We lead HAZOPs and What-If studies across batch and continuous processes and apply LOPA when a deeper risk-based evaluation is required.

Our facilitators don’t just manage checklists or push forms, we ask the right questions, engage the right people, and ensure the study produces usable, risk-based results that integrate into your PSM program. We tailor our approach to your team’s level of experience, your operational realities, and the complexity of your process.

Whether you're short-staffed, short on time, or just want the confidence that your analysis is done right, we deliver Simple Results for Safer Ops, not just another binder on the shelf.

What services do PSM consultants typically provide?

Process Safety Management (PSM) consultants provide a wide range of services designed to help facilities comply with OSHA 1910.119, strengthen safety systems, and improve day-to-day operational reliability. At a high level, these services often include:
- PSM Strategy Consulting – Advising on long-term PSM improvement plans, resource planning, and organizational structure.
- PSM Program Development & Simplification – Creating or refining written programs, procedures, and systems to ensure they are practical, understandable, and sustainable.
- PHA Facilitation – Leading HAZOPs, What-Ifs, and other hazard evaluations that meet regulatory expectations while driving useful insights.
- Compliance Audits – Conducting comprehensive audits of your PSM program to identify gaps, reduce risk, and prepare for inspections
.- PSM Training – Delivering tailored training for operators, engineers, and leadership, focused on what they need to know to maintain safe operations.
- Mechanical Integrity Support – Helping define, improve, or assess mechanical integrity systems for critical equipment.
- Incident Investigation Support – Facilitating root cause analyses and helping build internal investigation capacity.
- MOC and PSSR Coordination – Supporting or streamlining your Management of Change and Pre-Startup Safety Review processes to ensure compliance and consistent implementation.
- Advanced Process Safety Technical Studies – Providing specialized studies such as facility siting, overpressure protection evaluation, relief systems design, and consequence modeling.

At McMillen Process Safety, we focus on providing services that lead to usable results, not just deliverables that check the box. In addition to core PSM services, we specialize in growing and optimizing programs, facilitating PHAs in high- or low-complexity and staff-constrained environments, and providing outsourced PSM coordination when internal bandwidth is limited. Whether you’re building from the ground up or need targeted support in a specific area, our goal remains the same: Simple Results for Safer Ops.

Do you assist with OSHA or EPA inspection preparation?

Yes, we help facilities prepare for both OSHA inspections and EPA Risk Management Plan (RMP) inspections. Whether you’ve had findings in the past or simply want to be ready, proactive preparation is one of the most effective ways to reduce risk and demonstrate compliance.

At McMillen Process Safety, we perform PSM and RMP health checks, targeted evaluations that highlight the same documentation gaps, implementation issues, and program weaknesses inspectors are likely to flag. We also prepare your team to speak clearly and confidently about your PSM or RMP systems, processes, and safety culture.

If you’ve received past citations, we work closely with you to resolve those findings effectively (see: Can you help us fix previous PSM citations or inspection findings?). And if you're approaching your triennial compliance audit or concerned about inspection readiness, we bring the same calm, experienced support (see: How do consultants help during a PSM audit or OSHA inspection?).

Whether we’re helping you get ahead of the curve or supporting you through a regulatory event, our goal is the same: Simple Results for Safer Ops.

How do consultants help during a PSM audit or OSHA inspection?

At McMillen Process Safety, we lead your required three-year PSM compliance audits, as outlined in OSHA 1910.119(o), with a focus on clarity, practicality, and results you can act on. We don't just point out gaps... we help you understand what matters, why it matters, and how to address it with a plan that fits your operation.

If you're facing a regulatory inspection from OSHA or another authority, we also offer targeted support to help you prepare. That includes reviewing documentation, identifying high-risk issues, coaching your team on how to respond, and being available to support communication with inspectors. We help you stay organized, informed, and confident throughout the process.

Whether we’re conducting your audit or helping you respond to a regulator, our approach is the same: provide calm, experienced support and deliver Simple Results for Safer Ops.

How do you protect sensitive operational or proprietary data?

We take data security seriously and we keep it simple, transparent, and effective. At McMillen Process Safety, we use secure, business-grade platforms including Google Workspace, Microsoft 365, SharePoint, and OneDrive to manage, share, and store project files. All devices are protected with Norton security software, and critical project data is routinely backed up to encrypted external hard drives. We’re also happy to sign non-disclosure agreements (NDAs) to formally protect your confidential information.

We follow a straightforward principle: only collect and retain what’s needed to support your project. No unnecessary copies, no clutter, and no exposure.

Whether we’re handling safety-critical documents, proprietary process data, or internal audit results, you can trust that your information stays secure. Just one more way we deliver Simple Results for Safer Ops.

What’s the ROI of good process safety performance?

Good process safety isn’t a cost center, it’s a value multiplier.

The ROI of strong process safety performance shows up everywhere: fewer unplanned outages, lower maintenance costs, fewer injuries, stronger compliance, better insurance positioning, and greater operational consistency. In short, it protects your people, your production, and your profit.

At McMillen Process Safety, we often help clients clarify the real cost of safety. Not just what you spend to stay compliant, but what you risk when programs are bloated, ineffective, or ignored. A well-structured, right-sized PSM system isn’t overhead. It’s a core part of operational discipline and business continuity.

Strong process safety gives you:
- Fewer surprises from equipment, people, or processes
- Greater uptime and reliability across operations
- Improved decision-making based on real risk
- Stronger culture and engagement from your team
- Regulatory confidence without scrambling or guesswork

In our experience, investing in clarity and control always pays off. And that’s exactly what we deliver. Simple Results for Safer Ops.

What kind of ROI can we expect from working with McMillen Process Safety?

The return on investment depends on your goals but our focus is always the same: helping you reduce risk, improve reliability, and simplify your process safety efforts so they actually work.

Some clients see ROI through fewer citations, better audit outcomes, or faster PHA completions. Others measure it in reduced downtime, increased internal confidence, or programs that finally get used instead of shelved. And for many, ROI is simply about preventing a costly or catastrophic incident before it happens.

Here’s what you can expect from us:
- Clarity on what matters and what doesn’t
- Efficiency in how we scope, structure, and execute
- Usable deliverables that actually move the needle
- Confidence that your systems are working, not just existing on paper

We don’t sell templates or generic programs. We deliver targeted solutions that fit your operation and that’s where real ROI starts.

Because fewer problems, more reliability, and less wasted time means better performance across the board. That’s the heart of Simple Results for Safer Ops.