Manufacturing Industry Solutions

Integrity and safety engineering for manufacturing facilities managing worker exposure during maintenance, changeover, and non-routine work.

INDUSTRIES NAVIGATION

Moving your facility from reactive maintenance to Predictive Integrity using AI-driven data modeling.

Why Manufacturing Facilities Need Engineering Strategy?

Manufacturing risk isn’t driven by large-scale process or hydrocarbon consequence, it is driven by direct worker exposure to mechanical, electrical, and stored-energy hazards during maintenance, changeover, and non-routine activity. Pure Integrity helps facilities close the gap between what’s written in a procedure and what actually happens on the floor.

Our Approach for Manufacturing

Risk Profile

Risk is driven by direct worker exposure to mechanical, electrical & stored-energy hazards during maintenance, changeover & non-routine activity not by large-scale process or hydrocarbon consequence.

Standards Applied

Lock-Out Tag-Out (LOTO) / energy-isolation principles aligned to local occupational safety regulation (e.g. DOSH Malaysia), Hazard Identification, Risk Assessment and Risk Control (HIRARC) per DOSH Malaysia’s Guidelines on HIRARC, and ISO 45001.

Typical Client Outcome

Reduction in isolation-related near-misses, and the number of equipment-specific LOTO procedures developed.

Common Challenges Across Industries

Services

Pure Integrity provides a full range of process safety, functional safety, and asset integrity services to support manufacturing facilities at every stage of the plant lifecycle.

HAZOP / HAZID Consultant

Identifying process hazards and operability issues before they become incidents.

Explore Service

SIL Determination & Verification

Establishing and verifying safety integrity levels for critical safety instrumented functions.

Explore Service

Risk Based Inspection (RBI)

Prioritising inspection effort based on risk, criticality & failure consequence.

Explore Service

Asset Integrity

Supporting safe, reliable, and fit-for-service assets throughout their operating life.

Explore Service

Functional Safety

Ensuring safety instrumented systems perform reliably across their full lifecycle.

Explore Service

CHALLENGES WE SOLVE FOR MANUFACTURING

Inconsistent or Missing LOTO Procedures Per Equipment

Isolation procedures are often generic across machines that look similar but have different isolation points. We build equipment-specific procedures that close the gap between what's written and what's actually on the floor.

Human-Factor Risk Concentrated in Non-Routine Activity

The highest-risk moments, maintenance, changeover, troubleshooting — are also the least routine. We design procedures and training that account for unfamiliarity, rather than assuming operator competence carries through.

Isolation Applied But Not Verified Before Work Starts

LOTO is put in place but the zero-energy check is skipped, leaving residual energy exposure. We build a verification step into the procedure itself to close that gap.

Legacy Equipment Without Energy-Isolation Points Designed In

Older machinery wasn't built to modern isolation standards. We layer engineering solutions onto plant that was never designed with LOTO in mind.

HIRARC Treated as a Paperwork Exercise Rather Than a Live Tool

Generic, task-agnostic risk assessments get filed for audit purposes without translating into real floor controls. We tie HIRARC directly to LOTO and permit-to-work controls, and review it when the task, equipment, or process changes rather than leaving it static.

OUR METHODOLOGY

Johan Andak

Managing Director
Pure Integrity Sdn Bhd

Johan Andak is a process safety and operations specialist with decades of experience in the oil and gas, petrochemical, and energy sectors. As Managing Director of Pure Integrity, he provides strategic and technical leadership in process safety, functional safety, and risk assessment, supporting major projects across Southeast Asia, the North Sea, West Africa, Brazil, and Australasia.

Education & Certificate

Who We Work With

We have worked closely with many local and multi-national companies in Malaysia as well as overseas to fulfill their specific needs. Through close collaboration we have helped clients deliver safer, more reliable, and cost effective operations.