Total Injuries at Project Jan 2005 to date 7 8 13 48 ZERO  Lost Time Incidents
Company on Major Projects 2005
Company on Major Projects 2005 With 52C Plant Start-up “Exposures” removed….
Company  Hours & Incident Rates Last 2 Years Project MTIFR:  37.9 Rebuild TIFR:  27.33
Company Work Hours & Incident Rates Last 2 Years With Plant Start-up “Exposures” removed…. Project Millennium TIFR:  37.9 Suncor 52C Fire Rebuild TIFR:  27.33
IMPORTANT FIRST STEPS IN OUR RETURN TO WORLD CLASS SAFETY Oct  6 th :  Meeting With Client Oct 14 th :  Zero Tolerance Adopted Oct 15 th :  Functional Safety Plan Oct 19 th :  Aggressive A&D Policy Oct 20 th :  Fresh Start / Stand Down Oct 25 th :  Safety Incentive Program Nov 24 th :  2 nd  Stand Down/Follow-Up Nov 23 rd :  1 st  Safety Committee Insp. Nov 14 th :  1 st  Safety Committee Mtg. Mar 14 th : “Remember Charlie” Feb 14 th : Internal Audit Start (12 month moving TRIR)
Lessons Learned and  2006 Improvement Plan
Aggresive Manpower Curve Difficult to identify high-risk workers. Many low-experience workers (many competing projects). New Workers = New Foremen IDENTIFYING HIGH-RISK WORKERS LOW EXPERIENCE WORKERS MORE INCIDENTS = MORE INVESTIGATIONS NEW WORKERS  = NEW FOREMEN -Intervention Program -Mentor Program -Investigation Training -Foreman Orientation Things To Do: SAFETY INTERVENTION PROGRAM MENTOR PROGRAM CREW DISTRIBUTION SUPERVISOR – INCIDENT INVESTIGATION TRAINING FOREMAN ORIENTATION TRAINING REPORTS BY SUPERVISOR / IDENTIFY TRENDS
Aggressive Workday / Break Schedule Fatigue a possible factor.
-Revamp New-Hire Orientation: -Additional Focus on F.L.H.A. Process -Charlie Morecraft "Everyone's Responsibility" -Mentor Program Injuries from Hire Date 2005
Leadership for Safety Excellence: 60% Currently Trained 84% End of April 100% End of May Roles & Responsibilities Incident Investigation Canadian Model A&D WCB Return to Work Supervision Training SHORT TRAINING MODULES
2005 Incident-Specific Lessons Learned
SPRAINS / STRAINS 34% -Roll out B.B.S. -Add job rotation to Supervisor Training DEVELOP AND COMMUNICATE SAFE  MANUAL MATERIAL HANDLING JHA COMBINED = 50% BULK ARE PRECEDED BY “CRITICAL ERRORS”: EYES ON TASK MIND ON TASK LINE OF FIRE WILL BE ADDRESSED WITH INTRODUCTION OF BBS TRAINING WITH FRONT-LINE SUPERVISION: ENSURE ADEQUATE MANPOWER FOR TASKS ENSURE ROTATION OF WORKERS MATERIAL HANDLING 35% BALANCE / TRACTION / GRIP 27% STRUCK BY / AGAINST 23% OVER EXERTION / REPETATIVE STRAIN 15% Things To Do:
FOREIGN BODIES 23% -Roll out eye protection campaign in May PRIMARILY IN EYES FIRST INCIDENT REPORTED IN JUNE EYE PROTECTION AWARENESS CAMPAIGN TO BE LAUNCHED IN MAY EDUCATION EXPECTATIONS SUPERVISION WORKERS ACCOUNTABILITY Things To Do:
ILLNESS 15% -Build training to roll out before next startup phase. PRIMARILY EXPOSURE ALL INCIDENTS BETWEEN SEPT 22 ND  AND OCT 19 TH   DURING RAMP UP OF PLANT SHOULD BE ONE TIME ISSUE SIMILAR FUTURE SITUATIONS FORWARD LOOKING EDUCATION WORK WITH CLIENT TO ENSURE WORKFORCE EDUCATED AND PROPER PROTECTIVE MEASURES ARE TAKEN Things To Do: INEXPERIENCED WORKERS
80% OF MEDICAL AID INCIDENTS IN 2005 2 MA IMPROPER USE OF KNIVES 1 MA HANDLING SHARP MATERIALS 1 MA CONTACT WITH UNSHEATHED KNIFE BLADE LACERATIONS 12% CONTACT WITH SHARP EDGE 38% HANDLING SHARP MATERIALS 31% STRUCK BY / AGAINST 15% CONTACT WITH KNIFE BLADE 7% EYES ON TASK / MIND ON TASK / LINE OF FIRE BEHAVIOUR BASED SAFETY POOR PRACTICE EDUCATION EXPECTATIONS SUPERVISION WORKERS ACCOUNTABILITY
-NEW F.L.H.A. CARDS ROLLED OUT -REFOCUS ON INTENT, QUANTITY,  AND QUALITY -AVG 70% INCREASE SINCE LATE 2005 Field Level Hazard Assessments
A.B.E.A.R. Attitudes & Behaviour Eliminate All Risk FOCUS ON STATES LEADING TO CRITICAL ERRORS (to become) 95% OF ALL INJURIES CAUSED BY SINGLE PERSON Rushing Frustration Fatigue Complacency States Eyes not on task Mind not on task Line-of-fire Balance, traction, grip Errors (cause) Less Risk (which cause) Major Minor Close Calls Hazards More Risk Major Minor Close Calls Hazards with a Critical Error
Safety Awards at Safe Work Hour Milestones Communicate at Hire Has Raised Awareness Toward Small Incidents 2 nd  Phase (Specific Act Rewards) Rolling Out Soon MILESTONE SAFETY INCENTIVE PROGRAM SAFETY INCENTIVE PROGRAM
Identifies workers that have had 2 or more injuries within one year; or 1 incident within the first month. Safety awareness discussion Incident history review Incident frequency projection  (“If you continue at this rate…”) Hazard recognition and personal responsibility Increase personal awareness of safety performance Worker-driven action plan Hazard recognition training SAFETY INTERVENTION PROGRAM
NEW HIRE ORIENTATION INTERVENTION EDUCATION EXPECTATIONS ACCOUNTIBILITY INCENTIVES B.B.S.

Sample Safety Review 2006 Plan

  • 1.
    Total Injuries atProject Jan 2005 to date 7 8 13 48 ZERO Lost Time Incidents
  • 2.
    Company on MajorProjects 2005
  • 3.
    Company on MajorProjects 2005 With 52C Plant Start-up “Exposures” removed….
  • 4.
    Company Hours& Incident Rates Last 2 Years Project MTIFR: 37.9 Rebuild TIFR: 27.33
  • 5.
    Company Work Hours& Incident Rates Last 2 Years With Plant Start-up “Exposures” removed…. Project Millennium TIFR: 37.9 Suncor 52C Fire Rebuild TIFR: 27.33
  • 6.
    IMPORTANT FIRST STEPSIN OUR RETURN TO WORLD CLASS SAFETY Oct 6 th : Meeting With Client Oct 14 th : Zero Tolerance Adopted Oct 15 th : Functional Safety Plan Oct 19 th : Aggressive A&D Policy Oct 20 th : Fresh Start / Stand Down Oct 25 th : Safety Incentive Program Nov 24 th : 2 nd Stand Down/Follow-Up Nov 23 rd : 1 st Safety Committee Insp. Nov 14 th : 1 st Safety Committee Mtg. Mar 14 th : “Remember Charlie” Feb 14 th : Internal Audit Start (12 month moving TRIR)
  • 7.
    Lessons Learned and 2006 Improvement Plan
  • 8.
    Aggresive Manpower CurveDifficult to identify high-risk workers. Many low-experience workers (many competing projects). New Workers = New Foremen IDENTIFYING HIGH-RISK WORKERS LOW EXPERIENCE WORKERS MORE INCIDENTS = MORE INVESTIGATIONS NEW WORKERS = NEW FOREMEN -Intervention Program -Mentor Program -Investigation Training -Foreman Orientation Things To Do: SAFETY INTERVENTION PROGRAM MENTOR PROGRAM CREW DISTRIBUTION SUPERVISOR – INCIDENT INVESTIGATION TRAINING FOREMAN ORIENTATION TRAINING REPORTS BY SUPERVISOR / IDENTIFY TRENDS
  • 9.
    Aggressive Workday /Break Schedule Fatigue a possible factor.
  • 10.
    -Revamp New-Hire Orientation:-Additional Focus on F.L.H.A. Process -Charlie Morecraft "Everyone's Responsibility" -Mentor Program Injuries from Hire Date 2005
  • 11.
    Leadership for SafetyExcellence: 60% Currently Trained 84% End of April 100% End of May Roles & Responsibilities Incident Investigation Canadian Model A&D WCB Return to Work Supervision Training SHORT TRAINING MODULES
  • 12.
  • 13.
    SPRAINS / STRAINS34% -Roll out B.B.S. -Add job rotation to Supervisor Training DEVELOP AND COMMUNICATE SAFE MANUAL MATERIAL HANDLING JHA COMBINED = 50% BULK ARE PRECEDED BY “CRITICAL ERRORS”: EYES ON TASK MIND ON TASK LINE OF FIRE WILL BE ADDRESSED WITH INTRODUCTION OF BBS TRAINING WITH FRONT-LINE SUPERVISION: ENSURE ADEQUATE MANPOWER FOR TASKS ENSURE ROTATION OF WORKERS MATERIAL HANDLING 35% BALANCE / TRACTION / GRIP 27% STRUCK BY / AGAINST 23% OVER EXERTION / REPETATIVE STRAIN 15% Things To Do:
  • 14.
    FOREIGN BODIES 23%-Roll out eye protection campaign in May PRIMARILY IN EYES FIRST INCIDENT REPORTED IN JUNE EYE PROTECTION AWARENESS CAMPAIGN TO BE LAUNCHED IN MAY EDUCATION EXPECTATIONS SUPERVISION WORKERS ACCOUNTABILITY Things To Do:
  • 15.
    ILLNESS 15% -Buildtraining to roll out before next startup phase. PRIMARILY EXPOSURE ALL INCIDENTS BETWEEN SEPT 22 ND AND OCT 19 TH DURING RAMP UP OF PLANT SHOULD BE ONE TIME ISSUE SIMILAR FUTURE SITUATIONS FORWARD LOOKING EDUCATION WORK WITH CLIENT TO ENSURE WORKFORCE EDUCATED AND PROPER PROTECTIVE MEASURES ARE TAKEN Things To Do: INEXPERIENCED WORKERS
  • 16.
    80% OF MEDICALAID INCIDENTS IN 2005 2 MA IMPROPER USE OF KNIVES 1 MA HANDLING SHARP MATERIALS 1 MA CONTACT WITH UNSHEATHED KNIFE BLADE LACERATIONS 12% CONTACT WITH SHARP EDGE 38% HANDLING SHARP MATERIALS 31% STRUCK BY / AGAINST 15% CONTACT WITH KNIFE BLADE 7% EYES ON TASK / MIND ON TASK / LINE OF FIRE BEHAVIOUR BASED SAFETY POOR PRACTICE EDUCATION EXPECTATIONS SUPERVISION WORKERS ACCOUNTABILITY
  • 17.
    -NEW F.L.H.A. CARDSROLLED OUT -REFOCUS ON INTENT, QUANTITY, AND QUALITY -AVG 70% INCREASE SINCE LATE 2005 Field Level Hazard Assessments
  • 18.
    A.B.E.A.R. Attitudes &Behaviour Eliminate All Risk FOCUS ON STATES LEADING TO CRITICAL ERRORS (to become) 95% OF ALL INJURIES CAUSED BY SINGLE PERSON Rushing Frustration Fatigue Complacency States Eyes not on task Mind not on task Line-of-fire Balance, traction, grip Errors (cause) Less Risk (which cause) Major Minor Close Calls Hazards More Risk Major Minor Close Calls Hazards with a Critical Error
  • 19.
    Safety Awards atSafe Work Hour Milestones Communicate at Hire Has Raised Awareness Toward Small Incidents 2 nd Phase (Specific Act Rewards) Rolling Out Soon MILESTONE SAFETY INCENTIVE PROGRAM SAFETY INCENTIVE PROGRAM
  • 20.
    Identifies workers thathave had 2 or more injuries within one year; or 1 incident within the first month. Safety awareness discussion Incident history review Incident frequency projection (“If you continue at this rate…”) Hazard recognition and personal responsibility Increase personal awareness of safety performance Worker-driven action plan Hazard recognition training SAFETY INTERVENTION PROGRAM
  • 21.
    NEW HIRE ORIENTATIONINTERVENTION EDUCATION EXPECTATIONS ACCOUNTIBILITY INCENTIVES B.B.S.