Transcript Slide 1

CII Eastern Region Initiative
Safety Symposium And Exposition 2012
Behavioural Safety Psychology and its components
RAW MATERIAL
QUALITY PRODUCT
OUTPU
T
To get right output, Safety is not an option,
but a sustainability issue !
SMILING PEOPLE
WORKFORCE
INPUT
4th Oct 2012
A Glimpse Into “The Factories Act 1948”
Every Occupier Shall –
(a) ensure, so far as is reasonably practicable, the health, safety and welfare of all
workers while they are at work in the factory:
(b) provide and maintain plant and systems of work in the factory that are safe and
without risks to health:
(c) make arrangements for ensuring safety and absence of risks to health in
connection with the use, handling, storage and transport of articles and substances:
(d) provide necessary information , instruction, training and supervision for the health
and safety of all workers:
(e) maintain all places of work in the factory in a condition that is safe and without risks
to health:
(f) provide and maintain such working environment in the factory that is safe, without
risks to health and with adequate facilities and arrangements for welfare of workers.
All of above and more get elaborated in the rules
Safety @ Workplace combines Environment,
Individual & Behaviour to eliminate accidents
CULTURE & BEHAVIOUR
What the person does on job
• observation and feedback process;
• formal review of observation data;
• improvement goals,
• reinforcement for improvement
• involvement and ownership
Behaviour
People / Individuals
CAPABILITIES, TRAINING &
EXPERIENCE
e.g. SOPs, Culture, Risk Assessments
Spillage procedures
Environment
PLANT & EQUIPMENT,
CONTROLS, TASKS
e.g. Hazard Studies, PHR, SHE
Critical Equipment, Plant
Modifications., Guarding
Time
Most Injuries caused by:
“Unsafe acts”, “at risk” behaviours”
and “poor decisions”
AND NOT DUE TO CONDITIONS
AND EQUIPMENT.
Behavioural Safety?
…..process that helps an individual at work and off work to
understand / identify and choose a safe behavior over an unsafe one
• Conceptually easy to understand but difficult to implement and sustain
• Requires high commitment levels of the senior leadership team
• Requires involvement of employees across the organisation.
• Creates an atmosphere of transparency within the organisation
• Tight accountability in place
The Process Sets in a culture where “behaviour is managed”
Safety Excellence Journey @ TCIL...the start
Prior to 2010:
- Approach towards safety was “reactive” and “compliance” focused.
Need to change!!
- Stagnating safety records and general feeling “not a safe place”
- We were expanding from X to 2X (and space was a constraint)
SO?
-Help sought from Tata Steel and initiated the Journey
Challenges in implementing Change:
- Non-reporting unsafe incidents was common
- Safety as safety department’s responsibility and not “line responsibility”
Health and Safety Policy…..for
alignment And Decision Making
BELIEF:
The Safety and Health of all the people who work in and with The Tinplate
Company Of India Limited is our number one priority.
PRINCIPLES:
• All injuries and work related illness can and must be prevented.
• All employees and contractors are responsible for their own health and
safety and that of their colleagues, with management accountable.
• Employee engagement and training is essential.
• Working safely is a condition of employment for all employees / contractors
• Excellence in health and safety drives excellent business results.
• Safety and health is integrated into all our business management systems
and processes.
Safety management structure….2010
UCMs part of all committees and DICs
Four Apex Safety Sub Committees
2012
Audit and
Training And
Contractor Safety and
Standards,
Observation Communication Occupational Health
Procedures
Safety
Fire
Committee
Rules and
2011
Positive
Isolation
Committee
Five Divisional Implementation Committees(DICs)
2012
CRMs
Coating lines
Plant Services
Projects
General Services Medical Services
Divisions and Departments
Safety Department now plays role of coordinator,
consults line managers and advises senior management
Policy Management Daily Management
Apex Safety Council (Chaired By MD)
Standards Rules & Procedures – Key to
deployment and sustenance of systems
We streamlined ourselves through priortization based on “thrust areas” identified
Safety standards made
- Book formally inaugurated
- Made available safety portal
Deployment Through
-Checklists based on
standards for audits
- Audits based on standards
Till date, made 40 Safety Standards, 39 Training Modules
on standards, 24 Checklists based on standards
Standards will form basis of disciplinary actions once
thorough communication and training has been done
Audit & Observation – to drive behavioral
change and compliance to procedures
Observations
logging
standardised / mandatory
System for logging of SOs
Quarterly mock drills with
reportage and compliance.
Incidents reportage
Logging within 24 hr
Online PIR System
Recognizing “Good Citizens”
thru gifts or memos
Results
SO logging – Increased from 50%
level to 90% in Feb.’12 and
sustained
Analysis of data and sharing with
line managers
Biggest achievement has been in reportage of incidents
Contractor Safety & Occupational Health –
recognize them as partners in the journey
Improved ownership amongst employees for contract workmen
Three step of CSM implemented Initiated concept of Wellness @ workplace
General safety
guidelines with contract
OH hazard matrix
Training to Contract employees
Tool box meetings by contract workmen
Tight fitting cloths including female employees
Positive isolation
Identification & implementation progress…….
Trials at 6-Hi1 – 7Jan’12
Physical identification of equipments
Kickoff of Positive Isolation
process at 6-Hi2
INJURY ANALYSIS
42% in age 20-30, 34% being trainees, 44% in A shift
Part of the body
6HI
1
1 1
CRANE
4
2 1
CPL
1
3
2
2
ANN
Cause Wise
Face/Fore
head
Shoulder
Arm
1
Struck by sheet
Struck against
sheet
6
7
Struck against
object
TM
7
Hand
10
PIC
2
7
DEG
Finger
4
Pressed
between /under
object
4
Mech Maint
32% at Temper Mill
77 % related to hand / Finger
PPE
1
Nature of injury
5
8
5
1
2
44% Minor Cut Injuries
Employee
1
9
N.A.
Not
Provided
5
Hand gloves using not effective
3
Contractor
7
9
Not Available
9
SOP needs revision
Age Wise
0
Shift wise
4
20-30
10
Trainee
4
4
11
A
31-40
10
41-50
51-60
Followed
Not followed
NOT USED
Permanent
10
SOP
USED
2
Contusion
Sprain
Abrasion
L.W.
Minor cut
Acid Burn
Most Related to Manual material handling
6
B
C
What gets measured, gets attention, and
then action can follow..…
Standardised tracking and review of relevant data is a
MUST and helps to calibrate with other organizations
•
•
•
•
•
•
Identify Focus Areas, based on Analysis of previous year’s injuries
Meetings to start with safety pause – “constantly raising awareness”
Safety –first agenda for all “Communication” meetings
Weekly safety observation by all executives
Include union members in all decisions related to safety
Create culture to promote Reportage Of Incidents “IMMEDIATELY”
Some Parallel Activities….create visible
changes to communicate Safety is important
Key Performance Indicator
Senior leadership / CEO role:
16
“We care”
Words / action / involvement 14
• Weekly 2-hour observation (it 12
is a contact sport!)
10
• Hi potential, experienced
8
talent chosen to lead
6
• Attended first training
program of company (3 days) 4
• Consequence management 2
on the MD
0
• Regular assessment of
performance and make it
Board agenda
LTIFR (Lost Time Injury Frequency Rate)
14.69
13.31
4.68
2.42
1.33
2008 - 09
2009 - 10
2010 - 11
2011 - 12
2012 - 13
2013 - 14
While Improvement is visible,
a long way to go …
Success lies in involvement of employees at all levels and being accountable
SAFETY EXCELLENCE JOURNEY
Processes
•Safety Observations and
online logging
•Reconstitution of safety
committees
•Housekeeping Audits
•Incident investigations
•Hazard Identification
• PIR Reportage of
Incident
•Tool Box meetings
•Contractor safety
management
•Positive Isolation
launched
•Tight fitting dress
for lady employees
•Fatality Risk Control
Plan
•Contractor site
Audit
•Focus on Fool
proofing
•Positive Isolation
implemented
Reviews
•Safety Apex council
• Sub Committees
• Divisional
Implementation
Committees
•Audit by Corporate
safety –Tata Steel
•Safety Standard
Audits
•Union President
conducting
observations
Training /
Communication
•Safety for plant
managers (for officers )
•Training on Standards
•Incident Investigation
•Housekeeping & 5S
•Theme based months
•EAIS (for workers )
•Positive Isolation
•Contractor safety
management
• Daily on line
reporting
•FRCP
•Nukkad Natak
•Positives Isolation
•Road Signages
2010
2011
2012
WAY AHEAD……
• Housekeeping: continuous improvement
• Differential training program for younger age group
•Capturing fatality potentials
•Compliance to and revisiting SOPs
•Strengthen rescue management system
Few personal thoughts
• Any change management requires personal involvement
• Prioritisation of change opportunities is important
• Management by Facts ensures a common language and rationale
• Training, Communication, Personal contact, systems and procedures
• Reward and Recognition as also Consequence Management
• Learn from others
Business Excellence Core Values and Safety Excellence Journey:
Valuing Workforce members and Partners
Management by Fact
Systems Perspective
RESULT OF THE MEDICAL SURVEY
Total = 125 persons were tested
(more than 50 years of age )
Out of these 125 persons only 7
persons were found to be Healthy.
Out of these 7 Healthy persons only 3
were given a comment of “Keep it Up”
SL
Diseases – Tested for
1
HT =Hypertension
2
DM= Diabetes Mellitus
3
IHD= Ishemic Heart disease
4
Dyslipidemia = High Cholesterol
5
Sinus Bradycardia
6
OA Knees = Osteoarthritis
7
CABG = Coronary Artery Bypass Graft
8
Hydrocele
9
Other = Renal Calculus, Cyst,
Cholelithiasis with Hydrocele, high
myopia, S.I.Cataract etc.
SOME STRESS RELIEVERS……ENJOY !!!!!
Laughter
Sports
Massage
Healthy Diet
Adequate
Sleep
Hobbies
Forgiveness
Yoga
visit us at www.tatatinplate.com