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Chemicals and Mining Case Study | Resilience Guard
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Case study · Manufacturing

Process safety continuity and high consequence resilience for a multinational industrial operator

Controlled continuity of hazardous operations: process safety, crisis escalation and recovery governance for chemicals and heavy industry.

Practitioner led since 2014 Led by John Zeppos, Founder and Group Managing Director DRI Accredited training provider Three BCI Global Awards 16+ EU Horizon research projects Trusted to train 3 of the Big Four
SectorChemicals and heavy industry
FootprintProduction and extraction across Europe and beyond
FrameworksISO 22301, NIS2 context
FocusProcess safety continuity

Business context: heavy industry resilience is safety critical resilience

In heavy industry, disruption cannot be managed through rapid restart alone; recovery must follow controlled safety sequencing:

  • Process safety exposure during uncontrolled operational interruption.
  • Complex OT environments and industrial control system dependency.
  • Environmental escalation risk under disruption events.
  • Regulatory scrutiny linked to high consequence industrial operations.
  • Supply chain dependency for essential chemical and industrial materials, under rising NIS2 era expectations.
How can hazardous industrial operations maintain controlled continuity and crisis readiness under high impact disruption, ensuring safety, compliance and operational stability?

The situation

The operator maintained complex industrial sites with varying maturity, and continuity planning was not fully integrated with process safety governance:

  • Inconsistent recovery objectives between facilities.
  • Limited integration between continuity governance and process safety controls.
  • OT disruption exposure not formally embedded into industrial resilience strategy.
  • No unified crisis escalation model for environmental and safety events.
  • Supplier and infrastructure dependency risk affecting hazardous operations.

How the engagement was built

Engagement architecture: Process safety continuity and high consequence resilience for a multinational industrial operatorExecutive assurance and crisis governance01Process safetycontinuityintegration02Controlled restartand recoverygovernance03OT resilience forindustrial controlenvironments04Crisis escalationfor high consequenceeventsISO 22301 aligned business impact analysis and evidence base
The engagement architecture: governance above, sector-specific pillars, an ISO 22301 evidence base beneath.

01Process safety continuity integration

Continuity governance built into process safety controls, so disruption response protects controlled stability first and production second.

02Controlled restart and recovery governance

Recovery sequencing designed around safe shutdown and controlled restart of hazardous processes, owned by engineering and continuity together.

03OT resilience for industrial control environments

Cyber disruption of control systems treated as a primary safety scenario, with integrated recovery across engineering and crisis leadership.

04Crisis escalation for high consequence events

One escalation model for safety, environmental, regulatory and stakeholder dimensions, exercised with site and group leadership.

What programmes of this maturity deliver

Consistent with the firm's experience across the sector, high maturity programmes of this kind typically achieve:

Typical outcome ranges of high maturity programmes0%50%100%Faster controlled recovery capability25 to 45%
Typical ranges across comparable high maturity programmes, not a single client claim.
  • Stronger crisis escalation clarity under safety critical disruption.
  • Improved regulatory and stakeholder confidence.
  • Enhanced resilience maturity across hazardous industrial sites.
Frequently asked questions: Heavy industry resilience
How does ISO 22301 apply to hazardous industrial operations?

It ensures safety critical processes, controlled recovery sequencing and continuity governance are measurable, auditable and aligned with regulator expectations.

Why is OT resilience essential in chemicals and mining?

Industrial operations depend on control systems for safety and stability. OT disruption can immediately escalate into hazardous conditions, requiring integrated recovery governance across engineering and crisis leadership.

How is environmental escalation handled in continuity planning?

Through a unified crisis escalation model that treats environmental, safety, regulatory and stakeholder dimensions as one event, with clear authority and rehearsed communications.

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