Transcript No Slide Title

Mid-Atlantic Safety and Health Alliance
2K10 Conference
United Steelworkers &
United States Steel
Joint Safety and Health
Auditing
April 29, 2010
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Purpose:
To assist in the
protection of every
employee within
U. S. Steel
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Safety – Our Key Core Value
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
To be a critical,
complementary safety
activity to the hard work
that is already taking
place within the safety
processes at the plants
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Establishing the foundation:
U. S. Steel and the United
Steelworkers (USW) agreed to an
increase in union involvement in
safety and health as part of a 2004
agreement on Joint Safety Activities
This included:
Establishment of the USW Corporate
Safety Coordinator for U. S. Steel
Setting the stage for Joint Safety
Audits starting in 2005
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Establishing the foundation:
Audit format – What Is audited?
Corporate safety expectations:
U. S. Steel Life Threatening Safety
Standard Practices:
- Energy Control
- Elevated Work and Fall Protection
- Confined Space Entry
- Mobile Equipment Hazards
- EOT Crane Hazards
- Gas Hazard Management
- In-Plant Railroad Operations
- Molten Metal Protection
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Establishing the foundation:
Audit format:
U. S. Steel Life Threatening Safety
Standard Practices:
- Each practice is broken down
into a checklist of key practice
items
- Written plant documentation
- Training efforts on the practice
- Key observations of the practice
implementation on the shop
floor
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
U. S. Steel Life Threatening Safety
Standard Practices
Written Life Threatening Practice
Implementation
Training
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Energy Control Program Audit
Purpose: The review of the Energy Control Program is to determine the thoroughness of the program's
implementation. It is to include a written program review, review of training materials and training records, and a
review of the programs implementation/integration into the facility. A review of employee knowledge through an
interview process will be conducted by the auditors assigned .
Written Facility Program:
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Is a written facility lock out program in place? (MUST BE PRESENTED)
In lieu of a facility program are the Corporate Guidelines utilized?
(These are acceptable, if in place)
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Does the facility program contain the program elements detailed in the
corporate guidelines?
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Are formal Energy Control Procedures developed and readily available
for equipment with more than one energy source?
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Are the Energy control procedures up-to-date? (Reviewed/revised in the
last year? Ask if the department keeps hard copies and check the
document for the required review date? Is it current?)
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Are procedures in place for maintaining the continuity of energy control
across shifts?
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Is the forceful lock removal procedure in place and used? (Ask to see
completed forms)
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Are the usage of each color lock explained in the program?
Y/N
Comments
Score ()
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Training:
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Has documented Energy Control Program Training
been conducted for all affected and authorized
employees?
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Do the training materials contain the program elements
of the corporate program?
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Does training both initial and refresher include a
hands-on lock out component?
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Do facility training records reflect both initial and
refresher training?
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Are all lock types & unique color thoroughly explained
in the training (personal, department,
continuation or carry over, and out of service
locks).
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Are the usage of lock boxes thoroughly explained?
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Is the usage of the lock placement verification form
included in the training?
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Is the usage of the forceful lock removal form
thoroughly covered?
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Do employees have a thorough knowledge of the
program and how to implement? (The interview
process will cover this)
Y/N
Comments
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Field Verification: Identify lock out activity in place.
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Were pre-job instructions involving the lock out given
to the employees (verbal or written)?
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Is the employee's lock(s) used in a lock out activity
properly colored and identified per the facility
program? How many keys are there?
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Has the lock out activity properly followed the
appropriate Energy Control Procedure
(Example: sequence of isolation and lock
placement?)
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In a group lock out activity, if a lock box is in use, is
the lock verification form in place and
completed properly?
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Are all personnel working on the task accounted for
on the lock box?
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Is verification of energy isolation conducted prior to
starting the task? If so how?
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If restraints are used (blocks, pins, cans, chains, etc.)
are they of an engineering design?
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Are Out of Service Locks & Tags in place for
equipment removed from service?
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Prior to placing the equipment back in service and to
release from the lock out, is a final inspection
performed for personnel, tools, equipment?
Y/N
Comments
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Establishing the foundation:
Audit format:
Interviews with employees (hourly
and salaried)
- Progress the safety process
has provided for their safety
- Addressing their needs
- Talking with peers from other
facilities – no retribution
- Education gained – Life
Threatening Practices questions
“Do they know the practice?”
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Safety Interview: Energy Control Program
Question
#
Question
Correct
Incorrect
Comments
What is the purpose of lockout/tagout/tryout? (To assure the
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hazards presented by equipment energy sources are controlled prior
to the equipment being worked upon.)
What types of energy sources must we be concerned
about? (Electrical, Pneumatic, Hydraulic, Stored, Gravity,
Radiation, Mechanical - (4 of 6 is correct)
What document tells how to effectively lock out a specific
piece of equipment? (The Energy Control Procedure)
What color is your personal safety lock? ( Location dependent,
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most locations - red, Granite City - blue)
How is you lock to be identified? (Permanent marking - normally
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name and number)
What do you do with the second or spare key to your
safety lock? (There is to be no second key)
Who is allowed to remove your lock besides yourself? (NO
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one!!!!)
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Establishing the foundation:
Audit format:
Physical conditions and
housekeeping:
- Compliance issues
- Recognized hazards
- U. S. Steel best-in-class
housekeeping and physical
conditions
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Electrical Control Rooms and Substations :
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Motor control rooms, motor control centers
and substations must be secured and locked.
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Warning signs must be posted (e.g. Danger
High Voltage/Authorized Personnel Only 13800 Volts).
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Clean dielectric rubber mats are required in
front of switchgear or breaker cabinets.
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Electrical panels are to be closed.
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Flammable and/or combustible material (i.e.
wood, cardboard, paper) is not to be stored
in proximity to electrical equipment. Metal
ladders are not to be used in the proximity of
electrical equipment.
Handrails
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Protection of open sided platforms and
walking/working surfaces must be complete
with no damaged and/or missing handrails,
mid-rails or toe boards.
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Steps with more than 4 risers must have
handrails.
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Establishing the foundation:
Make up of the Audit Teams:
- Union Safety Representatives
- Operating and Maintenance
Managers
- Safety Supervisors
Different viewpoints
Different safety skills
Different sets of eyes
All involved for the same reason –
Employee Safety
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Establishing the foundation:
 Make Up of the Audit Teams:
Each party selects their auditors
Based on mutual trust ensuring:
- Attitude is not an issue
- Strong commitment to safety
- Will work to get the task done
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Establishing the foundation:
Additional value for the Audit Team
- Seeing other operations
- Meeting like Managers and Union
Safety Representatives
- New ideas to take back
- Reinforcement of U. S. Steel
values and implementation
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Establishing the foundation:
Auditor training
1 day of training for new auditors
- Life Threatening Safety Standard
Practice review
- Physical conditions exercise
- Interview protocol
- Safe task evaluations
- Strain and sprain recognition
- Recordkeeping (U. S. Steel programs)
- Auditing as a team
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 History:
2005 activities:
- 15 audits of facilities
2006 activities:
- 1-day training class for all
auditors
- 16 audits of facilities
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
History:
2007 activities:
- Equal numbers USW Safety
Representatives and U. S. Steel
Managers
- 1 day of training for new
auditors
- 18 joint audits of facilities
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 History:
2008 activities:
- 1 day of training for new
auditors
- 17 joint audits of facilities
- The audits were conducted
while 2008 contract
negotiations were under way
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 History
2009 activities:
- Experienced auditors
- 8 audits of facilities in full
operation
2010 activities:
- 1-day training classes for new
auditors
- 17 audits scheduled starting
May 2
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 Auditing the plant:
Meet the night before:
- Introductions
- Determine strategy
- Set up teams and area
of responsibility
- Go over general rules
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 Auditing the plant:
Opening meeting with the
plant’s personnel
Set ground rules - No
discipline
Introduce teams and area
assignments
Go over plant rules
Arrangements for back turn
auditing
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 Auditing the plant:
Walk, Look and Listen
Research what we see if not
sure
Daily Close Out Meeting
- 3’s and 3’s
- Plans for the next day
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 Auditor’s meetings:
Daily calibration of progress
Reassignment of resources
Daily data input
End of week report writing
- Draft report of findings
and impressions
- Corrective action
spreadsheet
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 End of the Week Draft Report
and Spreadsheet preparation:
Meticulous detail and
geographically correct
Positive items reviewed
Items needing attention
Consensus of the team, not a
single person
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 Close Out Meeting :
The Audit Team presents its
consensus findings
Review the major issues
Sets timeline for plant responses
and distribution
Report circulated within one
week to copy list, which
includes Operating Vice
Presidents, Executive Vice
President and Union Officials
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 Follow up :
Monthly progress on corrective
actions are sent to corporate
office and tracked to completion
Corrective Actions completion
goals:
- 85% in 60 days
- 95% in 90 days
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
 Lessons learned :
Positive cooperative effort
Attitudes checked at the door
Consensus does happen
Definite improvements seen
Shift from conditions and
housekeeping to procedures, task
evaluations and better safety
practice implementation
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
Joint Safety and Health Auditing
Questions?
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Mid-Atlantic Safety and Health Alliance
2K10 Conference
United Steelworkers &
United States Steel
Joint Safety and Health
Auditing
April 29, 2010
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