Even the best-designed process safety systems can fail if people don’t consistently follow the required steps. Operational discipline — doing the right thing, the right way, every time — is one of the most powerful ways to prevent incidents. One of the simplest yet most effective tools for improving operational discipline is the humble checklist.
In his bestselling book The Checklist Manifesto, surgeon Atul Gawande showed how checklists dramatically reduce errors in complex, high-stakes environments. The same principle applies directly to process safety in the chemical and energy industries.
What Makes a Good Checklist?
Well-written checklists are not long instruction manuals. They are short, practical, and focused on the critical steps that matter most. According to Gawande and other experts, effective checklists:
- Are clear and concise — usually 5 to 9 items per checklist
- Use simple, unambiguous language
- Focus on the “killer items” — the steps that, if missed, can lead to serious problems
- Are designed to be used at the right moment (e.g., before startup, during a critical transition, or after maintenance)
- Include a pause point where the team actually stops and verifies each item
- Are regularly reviewed and improved based on real-world use
Industries That Use Checklists Successfully
Checklists have transformed performance in several high-risk fields:
- Aviation — Pilots use checklists for every phase of flight (pre-takeoff, landing, emergency procedures). This discipline has made commercial aviation one of the safest industries in the world.
- Healthcare — Surgical safety checklists have dramatically reduced complications and deaths in operating rooms worldwide.
- Astronauts & Space Programs — NASA relies heavily on detailed checklists for complex, dangerous operations where there is no room for error.
For example, in the fertilizer and process industries, rigorous checklist use during startup and reformer operations has been highlighted as “low-hanging fruit” for preventing incidents. Historical analysis by Norsk Hydro showed that better inspections and checklists could have prevented ~50% of incidents, leading to dramatic reductions in fatal accident rates and costs.
Applying Checklists in Process Safety
Use of checklists in the chemical, energy, and other industries is not new. Checklists have been successfully used for years as in the example above to support a wide range of activities, such as equipment startup, loading operations, safe work practices, etc., but possible expansion of their use as appropriate can help reduce the likelihood of human error and drive OD improvements to obtain improved program performance. They are particularly valuable for:
- Management of change (MOC) reviews
- Pre-startup safety reviews (PSSR)
- Lockout/tagout and safe work permitting
- Critical equipment inspections and testing
- Startup after shutdowns or maintenance
- Emergency response and shutdown procedures
- Loading and unloading operations
- Shift handover and startup/shutdown activities
When used properly, checklists help ensure that critical steps are not missed, even under time pressure, fatigue, or distractions. They also support a culture of discipline and continuous improvement.
Practical Tips for Implementing Checklists in Your Facility
- Keep them short and focused — avoid turning them into lengthy procedures.
- Involve the people who will actually use them in their development.
- Test them in the field and refine based on feedback.
- Use them as a tool, not a replacement for judgment and training.
- Review checklist compliance as part of your operational discipline metrics.
Checklists are not a sign of incompetence — they are a sign of professionalism and respect for the complexity of the work we do.
Misuse of Checklists
Problems I’ve most frequently seen during process safety audits include:
- Checklists are not used in the actual operation, but filled out later
- Checklists are pencil-whipped, with all checkmarks added quickly at one time
- Checklists lack actual field verification requirements
- Checklists are not fully completed, leaving sections blank or partially filled without comment
- Checklists do not include the names of workers/team or are not signed
- Checklist recommendations are not captured in tracking systems to ensure completion
- Checklist comments are not clearly described or vague/unclear
For example, in a specialized safety audit, we once observed a safety system valve on a reactor system was locked closed even though it was required to be locked open. The startup checklist had been incorrectly filled out and indicated the valve was open. The result was the loss of a key safety interlock that could have prevented a serious runaway reaction.
Checklists alone won’t eliminate all risks, but when combined with other strong operational discipline practices, they provide a reliable defense against human error. As the process industries continue to emphasize leading indicators like checklist compliance, facilities that implement them rigorously will see measurable improvements in safety performance and reliability.
Recommended Resources
- Atul Gawande, The Checklist Manifesto: How to Get Things Right
- CCPS, Guidelines on Conduct of Operations and Operational Discipline
- Is OD Your Greatest Opportunity for Improved Process Safety Performance?
- Your own site-specific procedures and checklists
Have you implemented checklists in your facility to support operational discipline? What has worked well, and what challenges have you encountered? Share your experiences in the comments or contact me at jim@psmnews.com.