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The culture of hydraulic safety
Every organisation has a culture, and every organisation has a different culture. Equally, every organisation has a culture around safety, which can often conflict with the culture around hydraulic systems. Since the inception of MDG41 - Guideline for Fluid Power Safety at Mines there has been an explosion of interest in the safety of hydraulic systems. From the early days of MDG41 there was a significant drop in reported hydraulic incidents reported to the regulator. Recently there has been a spike in fluid power related incidents around the industry which suggests there is a disconnect between the perceived and real dangers of fluid power systems. As we now see the industry growing and less experienced workers joining the industry we must ensure that we demonstrate the correct culture when dealing with hydraulic systems.
The culture of hydraulic safety
- 1.
- 3. “Hydraulic systems arenot supposed to leak”
- 4. “Hydraulic systems arenot supposed to leak” This guy is bonkers He’s never worked in our conditions Yeah… right What ever….
- 6. “Hydraulic systems arenot supposed to leak” Our conditions are terrible Some leaks we cannot get to Just keep machines running No time / gear
- 7.
- 8.
- 11. Our conditions are terrible Then (2012)& Now (2019)
- 12. “Hydraulic systems arenot supposed to leak”
- 16.
- 17. “The ideas, customs,and social behaviour of a particular group of people or society”
- 18. • MDG41 • FluidPower Management Plan
- 19. “Good intentions arenot enough…”
- 21. “What can Ido…?” I’m not high level management…. No-one around me is changing ….
- 23. Processes too complicated Complacency Lackof ownership
- 24. Move from policing safety cultureto one where people use the tools and follow procedures because they want to and know it is the best way.
- 25.
- 27. “Hydraulic systems arenot supposed to leak”
- 28.
Editor's Notes
- #2 Intro – workshop before hockey Fluid power is what we do – design, sim, investigation Training – site, C4 to Aqdv Dip
- #3 Hydraulics, Pascal 1600’s, Bernoulli 1700s, Brahmah & Armstrong 1800s Hydraulics hasn’t changed a lot – except energy density From 400psi – 2000psi – 6000 psi and above 400 l/min to 2500 l/min Faster & stronger Dendrobium – operator and trades training for Electricians and Mechanical Trades Daily and Pre start checks Oil level, temp and leaks….
- #4 What is going through your mind right now- Look around your table - What does everyone else at your table think And what responses would you expect to hear if asked at your site
- #6 Not just this site – a lot of mining operations Coal, hard, U/g & surface I ask them what makes them think this? Here is the top 4 that usually come up
- #7 Do these sound familiar? Let’s analyse each of these just a little further
- #8 Production production – Ben W spoke about fires being preventable With hydraulics - Safety beliefs pushed aside We know the potential results of leaks – its not just equipment damage Leaking electricity would fix straight away – hyd not same energy level Do we not believe the risks. No effect on environment?? Not visible to general public
- #9 …..offshore, under water trencher, underwater dozer Laying cables in great barrier reef – would leaks be ok Whats different – magic components, design, the people?
- #10 My work - Tasmania, Groote – NT north coast And Kurnell
- #11 400m from Coast at Kurnell Multiple systems – rig, winches, cranes National park – not a drop, scrutiny On board person monitoring 10kL each leg, 2500 l/min Could have gone wrong, but didn’t
- #12 12cm29 – UGM overhaul Risk identification, engineer solution Same hoses – service life not failure
- #13 What is it that stops us believing hydraulic systems should be leak free Other industries - milk
- #14 Food processing – Tatura milk @ Mildura Leak – food contamination – product line de-con
- #15 Auscott Cotton @ Narrabri Complex interesting hyd systems – not simple Large flows Damage to product
- #16 None of these industries have magic components, or magic designs. Not even unicorns, much to my daughters dismay Why……
- #17 . Why do our teams have the belief that it is ok for hydraulic systems to leak. Why do you walk past hydraulic systems that have leaks and accept that it is ok. What is different about these other industries It is the underlying belief – or culture.
- #18 ... An organization's culture is represented by the values which it truly lives by, Every organisation has a “culture”, every organisation has a culture around safety, which can often conflict with the culture around hydraulic systems. Clint & James – Overwhelm, culture helps this Where hyd culture comes from
- #19 Starts at MDG41 Site Fluid power management plan MDG41 love/hate – increase in energy density yet decrease in incidents – Mark W, more focus on the incidents we have Spike in incidents recently – safety bulletin earlier this year Disconnect between management plan and actions
- #20 To create good culture MDG41 Audits do not ensure safe systems
- #21 Mt Arthur – remote cameras for testing for damaged hoses Disconnect between intentions and actions
- #22 I don’t own the fluid power management plan There are others in the organisation that won’t/don’t believe we need to change My crew members would just laugh at me
- #23 Apprentice – 2nd / 3rd year Dev section, my trade hated working with them Ask, learn from them – tickets They help with machine setup for maint and repairs There are 3 things detracting from this culture
- #24 Go to notes
- #25 Simplifying mining maint A book of ideas Our people intrinsically motivated Answer = 2 things Ulan Engineers course – LSI Profiling, The culture must be part of this and it will require the companies, unions and regulators to all start working together as one united team to start improving the culture. Moving from policing safety culture to one where people use the tools and follow procedures because they want to and know it is the best way. remember that person that you intrinsically do things for
- #26 Mark F – Engage, Educate, Empower Leadership Engagement Every conversation needs to promote safety, every interaction – employees, supervisors, OEMs, contractors, management, visitors Encouragement – how can we improve this, what could you do to improve this situation, how can I support you to fix this Encourage your own team to improve their own culture
- #27 Just talking is not going to make it happen. Kinesthetic or tactile learners – feel the colour
- #28 Take a pause – things are better than they were, but cannot stop trying