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Procedia Engineering 138 (2016) 487 – 497

“SYMPHOS 2015”, 3rd International Symposium on Innovation and Technology in the Phosphate
Industry

“Protect and Sustain” certification of OCP

Ahmed SADIK*
a
Axe Centre, OCP Group Morocco

Abstract

As a leader in the Fertilizer and phosphate international market, OCP decided on April 2014 to get certification in compliance with
the IFA’s standard “Protect and Sustain”. This standard is relating to product stewardship through the value chain of the phosphate:
since the Research and Development to customer delivery.
This certification consists on the compliance, of OCP management system and standards relating to security and SHE issues, with
IFA’s standards and criteria summarized in the 12 principles of IFA.
The scope of this certification concerned Gantour-Safi integrated line from R&D to customer delivery, including mining operations,
processing, chemical units, port facilities, external storage, supply chain, commercial and marketing, sourcing and contracting.
The certification audit aims to check that Fertilizers and raw materials, additives and intermediate products are processed and
manufactured, handled, stored, distributed and used in a safe way.
To guaranty the success of this project in Five months, a task force was formed. This project team was motivated and exited to
achieve this goal on time.
The product stewardship performance of OCP was analyzed in September 2014 and OCP was awarded in IFA’s summit in
Marrakech on November 2014.
This award with a high score (product steward excellence) was a result of our commitment to reach a high level in safety, security
and sustainability.

©©2016
2015Published by Elsevier
The Authors. Ltd.by
Published This is an open
Elsevier Ltd.access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the Scientific Committee of SYMPHOS 2015.
Peer-review under responsibility of the Scientific Committee of SYMPHOS 2015
Keywords: OCP; Axe centre; certification; IFA; Protect and Sustain; product stewardship

* Corresponding author. Tel.: +212 661 893 511

E-mail address: [email protected]

1877-7058 © 2016 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the Scientific Committee of SYMPHOS 2015
doi:10.1016/j.proeng.2016.02.108
488 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497

1. Presentation to “Protect and Sustain” Certification

1.1. Protect and Sustain Certification

Product stewardship might be described as the "next step" in Safety, Health and Environmental (SHE) management,
a step that broadens SHE management beyond the factory gate to include wider issues such as security. In many
respects, it is about putting into place responsible business management processes across a product's lifecycle.
As a demonstration of the commitment to acting as good global citizens, IFA members have already signed up to
certain safety, health and environmental manufacturing standards – such as the IFA SHE Principles. Now, through the
industry-driven Protect & Sustain initiative, IFA members are looking to roll this commitment out to every aspect of
the product lifespan.
“While this de facto global fertilizer standard is voluntary, it provides an opportunity for IFA members to show
their commitment to reach a higher level of safety, security and sustainability.” [1].

1.2. IFA’s 12 SHE Principles

Developed in 2007 by IFA as a set of guiding principles for Security, Safety, Health and Environmental (SHE)
management. These twelve principles embody the membership’s commitment to responsible and sustainable fertilizer
production and use.

Table 1: IFA’s 12 Security, safety, health and environment Principles

1. All members shall demonstrate leadership and management commitment with regards to safety, security, health and environmental
issues in fertilizer production, distribution and sales.͒
2. All members shall strive for zero harm and adverse environmental impact whilst maintaining a healthy work place for all employees
and contractual staff.͒
3. All members shall ensure that safety, security, health and environment issues are integrated into their corporate policy and receive the
utmost importance and priority.͒
4. All members shall ensure adequate financial and human resources for continual improvement of safety, security, health and the
environment performance.͒
5. All members shall comply with local safety, security, health and environmental laws and strive to embrace international laws and best
practices as much as possible.͒
6. All members shall establish and improve their safety, security, health and environmental performance through annual objectives,
targets or key performance indicators.͒ ͒
7. All members shall establish adequate procedures and controls to ensure that safety, security, health and environment are not
jeopardized at any time or in any form.͒ ͒
8. All members shall ensure that all employees and contractual staff have the right competence and are adequately trained and informed
about safety, security, health and environment related to their specific activities, and shall encourage the participation of employees
and contractual staff for further improvements.
9. All members shall adhere to the principles of hazard and risk assessment in evaluating all their activities to ensure that safety,
security, health and environment standards are continually enhanced.͒
10. All members shall strive to subscribe to safety, security, health and environment management systems that will be subjected to internal
and external auditing.͒
11. All members shall voluntarily share information with regards to experiences and lessons related to safety, health and the environment
with all employees and contractual staff, and with other IFA members, unless under legal constraints or if the information is of
proprietary nature.͒ ͒
12. All members shall strive to continually promote safety, security, health and environmental matters to enhance the social
responsibility and accountability of the global fertilizer industry.
 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497 489

1.3. Protect and Sustain Vs ISO and OHSAS Standards:

Protect & Sustain covers the quality, environmental, health and safety aspects of the ISO 9001 and ISO 14001, as
well as the OHSAS 18001 certifications.
However, Responsible Care 14001 includes a product stewardship code but addresses the whole chemical industry,
while Protect & Sustain was tailored for fertilizers Industry only.

1.4. Protect and Sustain certification:

PS certification is a continuous improvement system that covers the four pillars of a sustainable business: Quality,
Environment, Health and Safety and Security.
It has a scoring mechanism to allow you to track progress, or compare the performance of similar sites.
It examined the entire activity to ensure that all measures are taken to guaranty safety and security in operations,
transportation and use of products. The check concerns the following six areas:
x Area 1: Management system
x Area 2: Product development and planning
x Area 3: Sourcing and contractor management
x Area 4: Manufacturing
x Area 5: Supply chain to customer
x Area 6: Marketing, sales and application

2. “Protect and Sustain” Certification’s process

2.1. Step 1: Register your organization

You have to register your organization (or division, in case of a larger organization) on this web site
(www.protectandsustain.org) and gain access to a broad range of resources and tools available to registered users of
this site.

2.2. Step 2: Read up

Develop a full understanding of product stewardship, its principles, its benefits and a wealth of detailed documentation
relevant to product stewardship practices and experiences.

2.3. Step 3: Assess your performance

Assess (critical way) your organization's current level of product stewardship management and identify areas of
excellence and areas for improvement. Compare your results with the standards recommended by the IFA Protect &
Sustain team. The Assessment tool used is : The P&S Evaluation tool.

2.4. Step 4: Validate your assessment

Have your self-assessment results desk reviewed and validated by external experts.

2.5. Step 5: Get certified

To have your organization certified as a recognized product steward via independent site audits. The certification
levels include Product Steward or Product Steward Excellence. The certification process is divided into 3 parts:
490 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497

2.5.1. Stage 1: Pre-audit preparation:

The organization has to select an independent third party (external experts) to Identify a representative list of sites over
the product lifespan and work out audit program together with independent third party. In this stage, you can request
a pre-audit.

2.5.2. Stage 2: On-site audit(s) by the independent third party.

The evaluation is based on Protect and Sustain checklist that contains 113 questions covering the six areas
previously mentioned [Table 2]

Table 2: Performance summary

Total # # of N/A Max Score % obtained

Evaluation area
of questions questions possible score* obtained of maximum
1. Management systems 23 46 0 0,0 %
2. Product development and plann 8 16 0 0,0 %

3. Sourcing and contractor manag 14 28 0 0,0 %

4. Manufacturing 24 48 0 0,0 %

5. Supply chain to the customer 33 66 0 0,0 %

6. Marketing & sales and applicat 11 22 0 0,0 %

Overall score 113 226 0 0,0 %

* Note: Maximum possible score should be adjusted if any question is not applicable (N/A) to the activity of the company

For every question, the auditor has to score 0, 1 or 2 [Table 3]. For questions scoring 0, improvement actions must
be identified and planned for execution and all questions are to be scored, unless not applicable (N/A) to the activity
of the company.
In case of “Not applicable” response, a company has to justify this answer by giving proofs.

Table 3: Interpretation of scoring of questions

Value Appreciation Action

Corrective action
0 Not acceptable
is required
Meets requirements
1 Acceptable
(improvement proposal possible)
Firmly in place
2 Acceptable
and adopted as a best practice
N/A Question is not applicable to the activity of the company

The result of the audit is to have a scoring [Table 2] and list of main findings including strengths and best practices,
Improvement proposals and Areas for corrective actions.
The Most common findings / observations concerns Contractor management, supplier evaluations, monitoring of
contractor activities, Security, access control, Housekeeping, Risk assessments (if don’t include all activities or have
not periodically been reviewed).
Depending on scoring result, the certificate could be IFA Product Steward (score between 60% and 80%) or IFA
Product Steward Excellence (score over 80%) [Figure 1].
 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497 491

a b

Fig. 1. (a) logo of IFA product steward Excellence ; (b) logo of IFA product steward

2.5.3. Stage 3: Mid-term review:

After the certification and within 18 months, the organization has to do a self-assessment reviewed and validated
by a third party. This document has to be sent to IFA’s technical committee.

3. OCP Axe Centre Case

3.1. Certification’s scope

The certification has concerned the product lifespan in all activities throughout the value chain. From R & D,
mining, production in the mine facilities and chemical plants, supply chain, procurement and purchasing,
subcontractors management, logistics to customers, marketing, sales and external storage in Brazil.

3.2. Project Organization

The axe centre’s product stewardship was analyzed and responsibilities were defined between different entities of
the organization. Thus, as shown in [figure 2], each entity has a clear responsibilities in the project. For example,
product development is the responsibility of R&D and Commercial departments, the transportation is the
responsibility of production and Commercial departments… Therefore, the project team (task force) is
multidisciplinary and represents all entities involved in the certification processes.
492 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497

Agronomists
OCP Foundation Commercial
R&D

Commercial
Achat matières
premières

Production

Production Production
Commercial

Production
Commercial

Fig. 2. OCP Stewardship Leader Roles and Responsibilities

3.3. Axe centre self-assessment

To have a reference in our organization, we have made two self –assessment operation in both Safi site and Gantour
site. The checklist was filled by team project. Stewardship questions in the checklist were aim to maximising Benefits,
and minimising Risks. Main questions are as follow:

3.3.1. Product development:

What are the requirements to health, environment and product quality?

What regulations shall have to be complied with?
What are the processing limitations for manufacturing of the product?
What should a product dossier contain?

3.3.2. Sourcing of materials:

What criteria should be used for selection of suppliers?

Will quality criteria should be set of the raw materials or additives to satisfy the quality requirements of the final
product?
Are there any health, safety or environmental risks associated with the materials?

3.3.3. Manufacturing:

How should contractors and service providers be selected?

Process risks, health hazards and environmental management?
How to deal with waste material and offspecs?
 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497 493

3.3.4. Packaging:

Which packaging material should be used?

What to print on the bag?
Advice on waste handling and recirculation of packaging materials?

3.3.5. Transportation:

What criteria should be used for selection of service providers?

How to ensure traceability to the end user?
Emergency plans and product safety information?

3.3.6. Storage:

What requirements should be set to warehouse standards?

Best practice storage operations?
How to deal with reclaimed and offspec materials?
How to deal with fires?

3.3.7. Marketing and sales:

Product safety information to customers?

How to respond to inquiries and complaints?

3.3.8. Product application and farmer services:

Advice on product use and application rates?

Information on safe use and handling of fertilizers?

The average score, of self-assessment, of Safi site was higher than Gantour’s one. Safi scored 83% against 63% for
Gantour [Table 4-5]

Table 4: Gantour self-assessment.

Results
Evaluation area # of questions Maximum score Obtained % obtained of
maximum
1. Management systems 23 46 27 58,7 %
2. Product development and planning 8 16 15 93,8 %
3. Sourcing and contracting 14 28 16 57,1 %
4. Manufacturing techniques 17 34 26 76,5 %
5. Supply chain to the customer 19 38 22 57,9 %
6. Marketing, sales and application 8 16 7 43,8 %
Average score 178 113 63%
494 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497

Table 5: Safi self-assessment

Results
Evaluation area # of questions Maximum score Obtained % obtained of
maximum
1. Management systems 23 46 42 91,3 %
2. Product development and planning 8 16 15 93,8 %
3. Sourcing and contracting 14 28 24 85,7 %
4. Manufacturing techniques 17 34 31 91,2 %
5. Supply chain to the customer 26 52 48 92,3 %
6. Marketing, sales and application 8 16 0 0,0 %
Average score 192 160 83%

3.4. Certification’s Roadmap

A task force was formed and members had their role clearly defined. After several meetings, the project had its
roadmap with a time line of certification. [Figures. 3-4]

Stewardship is a transversal topic… …which requires a dedicated task-force

Commercial Identify Task-force members and roles’

(1) Promote product stewardship
(2) Benchmark and share the best practices of other organizations
(3) Provide guidance for planning product stewardship improvements
(4) Take advantage of this certification in commercial negociation Set-up a kick-off meeting for the task-force

Industry – R&D Identify a partner (2 accredited agencies)

(1) Identify and evaluate parts of the life cycle where the greatest
improvements can be made.
(2) Identify areas of excellence and areas requiring further Trainings and communication campaign
improvement
(3) Demonstrate its performance in responsible production.
(4) Provide the basic structure and guidance for planning product
Validation of the self-assessment
stewardship improvements within the organization

Pre-audit and definition of actions plan

Public Affair – Public Relations
(1) Take advantage of this best management practices in government/business
negotiations, relations with stakeholders, attracting private investment… Certification as an IFA Product
Steward.

Fig. 3. Certification’s roadmap

Seven steps were defined to be certified, identify task-force members and roles, set-up a kick-off meeting for the
task force, identify a partner (accredited agency), give trainings to managers and task-force members and launch of a
campaign of communication, update and validate the self-assessment, Pre-audit and actions plan result of Gap analysis,
certification’s audit.
The first meeting of the Task force members was on May 2014 and it was a challenge to pass a successful audit
and to have the PS’s certification before the summit of IFA planned on 19 of November 2014.
 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497 495

We were faced to several difficulties, It was not easier to have experts for trainings (the only possibility was to start
trainings on the third week of June 2014) and we were conscious that to achieve this goal needed the involvement of
the entire organization. But our organization.

Fig. 4. Certification’s time line

Task-force members were reassured by top management commitment and a large work done in the field of security
and SHE.
All sites had engaged a huge program to improve our level and reach a world-class standards in fields of security
and SHE. The program called “zero incident” concerns the development and the deployment of SHE standards, the
coaching of managers by consultants experts from DuPont Company.

3.5. Strengths of OCP Axe Centre

When working together, task-force members renumbered many strengths that made the certification of OCP axe
centre possible in five months. We cite some of them as follow:
• Commitment of top management through the progress monitoring meetings, kick off meetings and closing
audits.
• High involvement of task-force members by organization of regular meetings and promotion of messages of
communication and mobilization.
• Development of a PS policy and launch a wide communication campaign about it.
• Establishment of SHE standards and testing procedures and mastery of risks relating to industrial operations,
commercial, suppliers,...
• Implementation of control system of the environmental impact of activities and products, waste management
and monitoring of discharges.
• Implementation of emergency response plans in industrial site, in the external stocks, and at transportation of
products to clients.
• Implementation of control system of product quality focused on customer needs.
• Implementation of monitoring system and control in regulatory compliance.
496 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497

3.6. Pre-audit and actions plan

The third party agency launched pre-audit and edited recommendations as results of Gap analysis. The general
score of that operation was excellent (88%). The total of actions was 56.
Some new procedures and best practices were recommended and concerns:
• Integration of security and SHE requirements within R & D activities
• Setting up security system and procedures to verify its effectiveness.
• Integration of security and SHE criteria in the selection of suppliers and customers.
• Development and deployment of SHE and security management procedures when referencing, choosing
providers and when evaluating contractors

3.7. Final audit

The score obtained in the final audit was excellent (90%) and OCP got IFA product steward Excellence.
Auditors notified the following strengths:
• Sharing common values by all staff
• Senior management and all employees commitment to improve working conditions in the sense of safety,
health, environment and security.
• Excellent housekeeping in all sites visited.
• Significant investments on devices related to plant security.
• Very ambitious and greatly resourced global training system with more and more interest in aspects of PS
(HSE & security)
• Large and quick responsiveness to the remarks of the Pre-Audit Phase.
• Actively monitors of market trends, regulations related to the products and best practices
• Active involvement of R & D structures as a support of operations in the new product development
activities, processes and sustainable development (smart fertilizer phasing out of some auxiliary products,
research on conditions of handling and storage of fertilizers, valorization of waste ...)
• Active communication and support to farmers for appropriate and sustainable use of fertilizers (human
resources, OCP caravans ...)
• Deployment of OCP PRODUCTION SYSTEM (OPS) at all operational levels.
• Deployment of governance and operational standards: PHA ADRPT, GIASE, and VOSE EVEPS

4. Benefits of PS certification

PS certification is a continuous improvement system that has many benefits. It reassures us that the organization
ensures:
• Safe working conditions
• Actions to Protect environment
• Safe environment for communities
• Good reputation for the organization
• More profitability for the organization
• Less risk for all stakeholders
Being certified PS will surely have a positive impact on our group; it is a competitive advantage that will allow
OCP to strengthen its leadership and strengthen its commitment to global food security.
Finally, it’s important to note that this is the first time that an OCP audit covers all activities along the value chain
and affects the entire life cycle of products. Thus it was an opportunity to play the synergy and positive competitiveness
between teams of the different entities of the organization: R&D, Production, purchasing and Contracting,
Commercial, communication and OCP Institute.
 Ahmed Sadik / Procedia Engineering 138 (2016) 487 – 497 497

Protect & Sustain Hall of Fame

23 IFA members, producing in 32 countries; all primaryu ntrients (N, P, K); plus
regular re-certifications

Countries (several companies requested certification for multiple places): Austria, Argentina,
Bahrain, Belgium, Brazil, Canada, Czech Republic, Croatia, France, Finland, Germany, Greece,
Hungary, Israel, Italy, Lithuania, Netherlands, Norway, Malaysia, Mexico, Morocco, Poland,
Portugal, Romania, Qatar, Spain, Sweden, South Africa, Trinidad and Tobago, UK, USA, Vietnam
… plus many more producer members from around the world are currently in the certification
pipeline!

Fig. 5. Our CEO and President receiving PS certificate in IFA’s Marrakech summit

Nomenclature

IFA International Fertilizer Industry Association

PS Protect and Sustain
SHE safety health and environment

References

[1] : IFA 2013 report.

[2]: http://www.protectandsustain.org/