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Consulting - Consulting
Written by Bryan Haywood   
Thursday, 25 March 2010 03:41

Bryan T. Haywood, M.S.
Founder & President

Bryan Haywood has over 20 years of experience in the chemical process safety and emergency response fields.  He began his career as a fire fighter/EMT while attending Murray State University, where he obtained his BS in Occupational Safety and Health.  Bryan has gone on to receive his Masters in Safety Engineering.

During his career, Bryan developed, implemented, and managed chemical process safety management systems for five Fortune 500 companies that were required to comply with OSHA’s Process Safety Management Standard and EPA’s Risk Management Plan Rule.  Four of these management systems achieved OSHA VPP status and, as a consultant, he played a major role at an additional nine sites obtaining VPP designation.  As a safety professional in the chemical and semiconductor industries, he held positions ranging from Safety Engineer to Corporate Safety and Health Manager with Westvaco, Great Lakes Chemical, General Electric Plastics, BFGoodrich Specialty Chemicals, and SUMCO Phoenix Corporation.

Bryan focuses his safety efforts in the Chemical Process Safety arena, where he has extensive experience in:

  • Developing and implementing overall PSM/RMP management systems
  • Facilitating Process Hazards Analyses (PHA)
  • Developing and implementing Mechanical Integrity Programs
  • Developing and implementing Operating Procedures
  • Developing and implementing Safe Work Practices
  • Developing and implementing Incident Investigation procedures and assisting with critical investigations as a subject matter expert
  • Training on Operating Procedures, Emergency Response
  • Auditing against OSHA std's, NFPA Codes, ASME Codes, API Codes, IIAR Bulletins, ANSI std's, Chlorine Institute, and dozens more

Bryan also has extensive experience with Emergency Planning and Response (Industrial Fire Brigades, HAZMAT, Confined Space and High-Angle Rescue, Transportation Emergency Response), hazardous materials management, fixed fire and foam protection systems, flammable liquids and gases, and combustible dusts.  Bryan maintains all his current emergency response certifications, and has obtained over 6,000 hours of technical training in Industrial Firefighting, Hazardous Materials and Technical Rescue (Confined Space, Trench, High-Angle), and Incident Command from recognized training organizations such as Texas A&M’s National Emergency Response and Rescue Training Center, Louisiana State University Fire and Emergency Training Institute,  U.S. Fire Administration’s National Fire Academy, The Security and Emergency Response Training Center, and the U.S. Department of Energy’s Nonproliferation Test and Evaluation Complex.  Bryan shares his two decades of emergency response experiences, in both private industry and public sector fire service, with approximately 500 students each year in the SAFTENG emergency response training courses taught around the world.

Bryan now runs his world renowned and award winning safety website ( and consulting business ( LLC), providing safety consulting services around the world. The website receives over three million visits a year from an ever growing list of who’s who in the safety profession. Over 100 companies and organizations sponsor the website with Corporate Memberships so that safety professionals and management teams within their organizations will have access to his library of real-life safety photos, safety and health training presentations, safe work procedures, the Daily Incident Alerts, and the Weekly Safety Newsletters. In all, more than 25,000 safety professionals in more than 80 countries around the world, as well as regulatory agencies such as Occupational Safety & Health Administration (OSHA), National Institute of Occupational Safety & Health (NIOSH), Environmental Protection Agency (EPA), The U.S. Chemical Safety Board (CSB), United Kingdom's Health & Safety Executive (HSE), Australia's Work Safe Victoria, British Columbia’s WORKSAFE, and many other government agencies around the world utilize the works of Bryan on a daily basis.

Bryan is an adjunct instructor at the University of Cincinnati's Fire Science Program, where he teaches Safety Management and Emergency Management courses.  His work has been featured in several books and publications, including Guidelines for Hazard Evaluation Procedures, Third Edition, American Institute of Chemical Engineers—Center for Chemical Process Safety, 2008; “Hazards of Nitrogen Asphyxiation,” U.S. Chemical Safety and Hazard Investigation Safety Bulletin No. 2003-10-B; and “Lockout/Tagout” in Process Heating, March 2003.

Click on the Testimonial tab to see what clients and former employers say about Bryan's safety knowledge, abilities, and passion for protecting workers.



Senior Safety Engineer
Assistant Area Director (retired)
OSHA Cincinnati Area Office, Region V

Dennis has over 39 years experience in the safety field, having worked for the Occupational Safety and Health Administration (OSHA) from 1972 until 2006.  In his time with OSHA, Dennis spent 25 years as a Compliance Safety and Health Officer (CSHO) and 8 years as the Assistant Area Director of the Cincinnati Area Office – Region V.   As the Assistant Area Director of the Cincinnati Area Office, Dennis had first level supervisory responsibilities over the CSHO’s in the discharge of their duties, as well as conducting compliance inspections for Region V.  Dennis also was directly involved in the following areas as the A.D.:

  • Voluntary Protection Program (VPP) assessments and approving certifications
  • Targeted Inspection Programs
  • Team Leader on over 70 fatality investigations and participated in hundreds more
  • Lead Informal Conferences with employers
  • Negotiated settlement agreements with employers
  • Team Leader on Chemical Special Emphasis Inspection Program in Region V
  • Team Leader on Petro Chemical Special Emphasis Inspection Program in Region V

As a CSHO for 25 years, Dennis conducted over 1,500 of wall-to-wall OSHA compliance audits, as well as OSHA’s targeted inspections and investigated employee safety and health complaints.

Over his 34 years with OSHA, Dennis became an OSHA resource for all regions in the general industry standards and their applicability to all types of work environments. Although Dennis has expertise in all general industry compliance matters, Dennis’s true expertise lies in Lockout/Tagout, Confined Spaces, Machine Guarding, Emergency Egress, Fire Protection, and Flammable Liquids.

Over his 39 year career Dennis graduated from Miami University with BS in History & Political Science and went on to complete Graduate Programs in Environmental Health & Safety Management at the University of Cincinnati.  Dennis also attended numerous training courses through OSHA and in the civilian sector.



Robert W. Johnson
Senior Chemical Engineer
President of Unwin Company - A "Partner in Safety"

Mr. Johnson is President of Unwin Company. He is an industry leader in the development and dissemination of risk analysis methods and risk management strategies. For the past 28 years, Mr. Johnson has helped clients prioritize risk reduction options, develop corporate and plant technical safety programs, identify inherently safer processes, train PHA team leaders, and analyze fire, explosion, and toxic release hazards.

Mr. Johnson currently serves as a member of the American Institute of Chemical Engineers (AIChE) Area 11a Committee, which sponsors the annual AIChE Loss Prevention Symposium, and the AIChE Safety and Chemical Engineering Education (SACHE) Committee, which promotes process safety in undergraduate chemical engineering programs. Mr. Johnson has served on the Risk Assessment subcommittee of the AIChE Center for Chemical Process Safety and has chaired the CCPS Long Range Planning Committee.

Among his many contributions to the loss prevention literature, Mr. Johnson was primary author of Essential Practices for Managing Chemical Reactivity Hazards and Guidelines for Safe Storage and Handling of Reactive Materials and co-author of Guidelines for Vapor Release Mitigation, Guidelines for Hazard Evaluation Procedures, Third Edition, all published by the AIChE Center for Chemical Process Safety.

Mr. Johnson has held Senior Engineer positions with Du Pont and with Hercules Incorporated. He holds BS and MS degrees in Chemical Engineering from Purdue University.


Steven W. Rudy
Senior Chemical Engineer
President of Unwin Company - A "Partner in Safety"

Mr. Rudy has been a risk management consultant to the chemical process industries since 1987. He has also consulted in the aerospace and nuclear power industries. He has accumulated expertise in a number of areas, including the development of risk-focused mechanical integrity programs, the facilitation of process hazard analyses, the preparation of operating, safe work practice and emergency response procedures, the development of administrative systems for process safety management, and quantitative risk assessment.

Mr. Rudy also specializes in the development of software to support risk management, risk analysis, and safety/production administration, having developed applications for numerous clients.

Mr. Rudy was co-author of Essential Practices for Managing Chemical Reactivity Hazards and Guidelines for Safe Storage and Handling of Reactive Materials.


Diana Gay, CIH
Senior Industrial Hygienist

Diana has extensive experience at all levels of the safety and health profession, from plant safety all the way to corporate safety management. In her distinguished career in the chemical industry Diana directed, coordinated and audited employee health and safety programs for corporate operations covering approximately 7,000 employees at 50+ plants located in the U.S.A. and around the world. She developed HSE Homepage on the company intranet providing a central reference for electronic versions of HSE manuals, incident reports, statistics and related internet links. She has testified as an expert witness for the company in hearings on contested OSHA citations before the Occupational Safety and Health Review Commission.

Diana's facilitation and management skills can not be surpassed. She:

  • Facilitated implementation of Behavioral Safety Observation process in both the U.S. and Europe
  • Lead a Task Force of company employees that developed "15 Key Elements of a Safety Program" for a chemical facility that are still a standard of excellence today
  • Developed safety and health compliance audit protocols and performed HSE audits of facilities in both the U.S.A. and internationally.
  • Was a key partner in Steering and Implementation teams for company-wide "E-Learning" systems for both training and document management, as well as developed computer-based training modules for HSE topics that are used as corporate standard training globally.

She has performed initial H & S assessments of new acquisitions and developed and aided in implementation of integration plans for achievement of company standards for these new acquisitions.


Rodney Mason
Construction Safety Coordinator

Rodney Mason has 23 years of experience in heavy industrial and power generation work, with extensive safety experience and numerous safety certifications.  His involvement in safety began during his time serving in the US Army, with specialty in explosives, nuclear, biological and chemical safety. Rodney currently holds the following safety certifications: Hazardous Waste, Lead Paint Abatement, Asbestos Abatement, Radiation Hazards, Scaffold Inspection, Class A CDL w/ Tanker, First Aid/CPR/AED; as well as being an Authorized OSHA Construction Outreach Instructor.  Rodney has extensive knowledge of computer hardware, diagnostics, repair, and the Internet.  He has advanced knowledge of Excel, with a working knowledge of MS Word and MS Access, as well as developmental work on relational databases on Safety with PocketPC 6.1 OS.

Rodney is available for a vast array of safety projects, but leads our construction safety projects, as well as turnaround projects at power plants.  Rodney has extensive experience working at major power plant projects, from new build combined cycle gas turbine/steam to small gas turbine peeker plants and a couple of coal fired plants; as well as doing new build chimney’s and repair ranging in height from 480’ to 1,000’.

Rodney enjoys teaching safety and has one of the best OSHA 10 & 30 hour construction safety courses in the industry.  Rodney also "fancy's" himself a computer guru who loves building databases for safety inspections, Injury/Illness management databases, etc.  If you have monthly reports that you would like to have done electronically, contact Rodney and see if he can help you out.

We brought Rodney on board for two simple safety KNOWLEDGE and his PASSION for safety!  Rodney states "I have had too many friends die doing the work we love to do. Mostly due to their own mistakes that they would not allow others to commit. My main goal was and is to make sure my men and women go home every night or morning to their families the same as when they left for work and to work for companies whose safety expectations met or exceed my own."


Charles J. Perry
Senior Emergency Response Instructor
Cincinnati Fire Department - District Chief (Retired)

Chief Perry has over 32 years experience in the emergency response field, having worked for the Cincinnati Fire Department from 1973 until 2000 and then as the Director of the Greater Cincinnati Hazardous Materials Unit from 2000-2005.  In his time with CFD, Charlie spent 16 years in senior leadership roles, retiring as a District Chief from CFD in 2000.   In his leadership roles at CFD and Cincinnati HAZMAT, Charlie was directly involved in:

  • Fire and HAZMAT Response and Investigations
  • Emergency Scene Management
  • Personnel Management and Training
  • Working with local industry in developing and implementing facility emergency action and response plans
  • Member of the Southwest Ohio Incident Management Assistance Team (IMAT)
  • Implementing the NOAA  Emergency Hazardous Materials Notification Project
  • Developing and Conducting WMD and HAZMAT Exercises and Tabletops for Emergency Responders and Industry

As an emergency responder for the past 32 years, Charlie has responded to and managed thousands of different types of emergencies of all shapes and sizes.  During this time he became a recognized expert in emergency scene management (e.g. Incident Command Systems) and he is now a lead instructor for LSU and Texas A&M Fire Schools.

Charlie is also a Qualified Department of Homeland Security Instructor on:

  • Incident Command
  • Incident Response to Terrorist Bombings
  • WMD Awareness
  • WMD Incident Management
  • Unified & Area Command
  • Emergency Response to Nuclear, Biological & Chemical Incidents
  • WMD & HAZMAT Emergency Operations
  • HAZMAT Sampling & Evidence Collection
  • WMD & HAZMAT Exercise Design

Charlie has received numerous awards over his distinguished career, including:

  • Leadership Award Nominee for the Syrian Shrine Firefighters Award for 2002 & 2003
  • Ohio EPA On Scene Coordinator’s Award
  • Risk Communication Award from the Greater Cincinnati Alliance for Chemical Safety
  • Chemical Education Foundation Community Chemical Product Stewardship Award Finalist
  • Award from Good Samaritan Hospital for the Development & Implementation of their Fire & Safety Plan, which won the Ohio Society for Hospital Engineers Award of Excellence
  • Commendation for Command Activities during the 1997 Cincinnati Floods
  • Commendation for Command Activities during the CSX Railroad Yard Fire

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