Safety is the foundation of operational success. According to the World Economic Forum (WEF), preventable injuries cost manufacturers 103 million workdays annually. That’s 103 million days of time and effort lost to issues that could have been avoided with the right processes in place.
One such process aimed at reducing injuries and delays is the pre-startup safety review (PSSR). What is PSSR in manufacturing? PSSR is a formal inspection carried out before new equipment is launched or existing equipment is restarted after a shutdown. Companies should also conduct a PSSR after any major repairs, modifications or installations.
Consistent application of PSSR processes can help prevent accidents by identifying safety or compliance gaps before they cause harm. PSSR also aligns with process safety management (PSM) best practices and regulatory expectations to help manufacturers ensure compliance.
Here’s what you need to know about building a PSSR program that simplifies safety procedures and reduces risk.
Why PSSR exists: Historical context and risk prevention
The first Industrial Revolution introduced machinery as an alternative to manual labor. The Second brought mass production and the recognition that reactive safety processes were not sufficient.
While post-mortem analysis of what went wrong helped improve response times when machines failed or workers were injured, this approach did nothing to anticipate failures. In response to growing safety concerns, the Occupational Health and Safety Administration (OSHA) introduced the Process Safety Management (PSM) standard in 1992, which established PSSR requirements.
Key hazards that PSSRs look to prevent include:
- Pressure and mechanical failures
- Chemical leaks and exposure
- Electrical risks
- Fire and explosion hazards
By taking a preventative rather than reactive approach to safety issues, PSSR programs help companies avoid costly and time-consuming errors that could lead to machine downtime and put team members in harm’s way.
What triggers a PSSR in manufacturing?
Several conditions can trigger a PSSR in manufacturing. They include:
- New equipment installation or modified facilities
- Major repairs or changes to design specifications
- Alteration of controls, instrumentation or safety systems
- Process restarts after extended downtime or seasonal shutdowns
PSSRs may also be triggered by internal policies that go beyond OSHA minimums for protecting machine uptime. For example, a chemical manufacturer might choose to carry out a PSSR after installing a new IIoT-connected sensor designed to measure temperature and pressure during a key preparation process.
While the process itself was never taken offline, and it is unlikely the new sensor will cause any issues with existing operations, the company may opt for a PSSR to test for any unexpected interactions and ensure comprehensive safety measures are taken.
Key components of a PSSR
Effective PSSRs cover multiple elements to reduce total risk. They also assign responsibility for each review step to a specific department or group, which helps mitigate the chance of stranded processes, that is, those that must be completed but aren’t owned by any team or executive, leaving them incomplete.
Common PSSR checklist items include:
- Engineering design verification
- Equipment integrity and mechanical inspection
- Control systems and alarm tests
- Safety device checks, such as interlocks, stops and emergency procedures
- Hazardous energy control and lockout/tagout safety procedures
- Quality of installation evaluations for procedures such as piping, mounting and alignment
- Confirmation of material compatibility
- Ensuring trained personnel are ready on shift
- Updating written procedures for startup, shutdown and emergencies
PSSR processes also benefit from multidisciplinary review. By collecting insights from environmental, health and safety (EHS) teams, engineering staff, maintenance personnel and operations employees, manufacturers can identify opportunities for PSSR improvements.
PSSR and OSHA/PSM compliance
Completion and documentation of PSSR is required under OSHA Standard 1910.119: Process safety management of highly hazardous chemicals.
PSSR is one key step in PSM and is mandated for all hazardous processes. Successful completion of PSSR meets OSHA regulatory expectations for “safe to operate” verification and provides audit-ready documentation for insurance providers, government inspections and corporate compliance reviews.
It’s worth noting that while PSSR is not required for non-PSM environments, many companies still carry out pre-startup safety reviews to improve reliability and reduce the risk of injury.
The role of maintenance and reliability in PSSR success
Effective PSSR processes depend on data. The more information companies have, the better prepared they are to avoid potential safety risks. As a result, maintenance and reliability data play a key role in PSSR. Collecting and applying this data relies on both people and technology.
For example, maintenance technicians can verify the performance of lubrication systems, ensure the precision of alignment and torque specifications and track any issues with vibration, temperature or pressure. In addition, they can compare current asset conditions to maintenance baselines and report any discrepancies.
Technology solutions are also essential. The benefits of a CMMS (computerized maintenance management system) include ensuring that work orders are closed, assigning corrective follow-up actions and updating asset lifecycle records.
Overlooking maintenance data can result in significant performance issues and increased risk. Consider a high-volume chemical pump taken offline for an upgrade. A review of maintenance data shows two worrying trends: increased vibration and pressure over the past six months.
If the pump is brought back online without addressing these issues, the results could range from reduced process efficiency to catastrophic seal failure.
Digital tools supporting PSSR execution
As noted above, technology plays a key role in effective PSSR frameworks. This role is tied in part to documentation challenges because PSSRs are not carried out on a regular schedule, but are instead tied to new startups, upgrades or post-repair reinitializations. It can be easy for companies to lose track of key PSSR documentation. The result is lost time and effort spent rebuilding key documentation libraries.
Technology solutions such as CMMS, manufacturing execution systems (MES) and IIoT networks can help improve consistency and enhance data verification.
Popular technologies improving industrial safety include:
- Centralized digital checklists: Using connected tools to create centralized digital checklists reduces variation in assessments. This also enables teams to reuse common checklist frameworks rather than starting from scratch for each new PSSR.
- Real-time inspections: Mobile tools combined with connected IIoT sensors set the stage for real-time inspections. This data identifies emerging issues and lets companies take targeted action.
- Records storage and management: Comprehensive records storage and management both improve compliance and lay the groundwork for predictive analytics that enhance machine health monitoring.
By integrating PSSR data into manufacturing operations, companies are better prepared to carry out risk assessments, develop proactive asset health strategies and create preventative maintenance schedules.
Common PSSR challenges and how to address them
PSSR programs aren’t foolproof. For example, inefficient assessment and evaluation practices can lead to bottlenecks, which in turn delay startups and can lead to budget overruns.
When it comes to PSSR programs, three challenges are common:
1. Poor coordination across teams. If teams do not coordinate effectively, the result may be wasted time or effort. Lack of coordination can also lead to missed or incomplete data collection, which can cause unexpected failures. For example, if two teams responsible for PSSRs both assume the other has collected key pressure and temperature data, the result could be equipment failure or worker injury.
2. Incomplete documentation. Missing documentation makes it challenging for teams to determine next steps, especially if they are under pressure to get machines back up and running. Time taken to create new standard operating procedures or revise existing process safety information may result in bottlenecks.
3. Rushed timelines. PSSRs are deliberate and focused assessments of potential risk. Setting too-tight timelines leads to errors and miscalculations that are costly and dangerous.
Addressing these challenges starts with best practices for industrial maintenance safety. First is standardized training—ensuring that both maintenance and front-line staff have the skills and knowledge necessary to carry out PSSR assessments.
Next are defined RACI roles. RACI stands for Responsible, Accountable, Consulted and Informed. Those responsible carry out PSSR assessments; those accountable own the work and give final approval. Those consulted provide input into the process, and those informed are kept up to date. In a manufacturing company, machine operators are often responsible, a C-suite executive such as the chief operating officer (COO) is accountable, highly skilled maintenance experts are consulted and CEOs are informed.
Finally, manufacturers need to carry out post-review performance audits. These audits help identify where PSSR processes were successful and where improvements are necessary to reduce risk and streamline startups.
PSSR as a driver of safety culture and operational excellence
While the primary purpose of PSSR programs is to reduce hazard risks, these reviews can also drive improved safety culture and enhanced operational standards.
An effective PSSR program offers multiple benefits, such as:
- Reduced reworks, delays and injury claims
- Improved uptime
- Enhanced EHS and regulatory posture
- Clear organizational commitment to worker safety
Simplifying safety with PSSR
PSSRs have a simple purpose: proactive safety. Instead of waiting until machines fail or staff are injured, PSSR programs help identify and address safety issues before equipment is restarted after repair, upgrade or new installation.
Successful PSSR programs share a common component: consistency. By creating a structured, repeatable process to assess and mitigate potential risks, companies can ensure OSHA compliance, align cross-departmental operations and create a culture of safety that both reduces risk and improves uptime.
Enhance your PSSR program performance with ATS. Let’s talk.
References
World Economic Forum. (2025, September 16). Why manufacturing companies now see safe workplaces as a competitive advantage. World Economic Forum. https://www.weforum.org/stories/2025/09/manufacturing-safe-workplaces-talent-productivity/
Occupational Safety and Health Administration. (n.d.). 1910.119 – Process safety management of highly hazardous chemicals. OSHA. https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.119
Center for Chemical Process Safety. (2014, November). Thirty years ago – An LPG tragedy. AIChE Process Safety Beacon. https://www.aiche.org/sites/default/files/beacon-article/2014-11-Beacon-English.pdf
