2
Historical View
• Increase in the number of Contractors used in Xstrata.
• The number of serious Accidents and High Potential Risk Incidents increased.
• Delays and frustration with current processes (medicals/induction/first aid/licensing).
• Contractors employed outside there scope of work.
• Two fatalities involving Contractors during 2007.
3
Fatality SWB – Komatsu Employee - 9 January 2007
Close up viewPosition of safety strut with cab elevated
Position where assistant lay to adjust pressures
4
Causes
Direct• Design of support strut did not make provision for it to
be locked out• Machine shudder due to hydraulic faultUnderlying• Risk awareness• Modifications to ADT/Equipment• Safety devices ineffective• “Pirate” parts• Contractor management –sub contractors• Access control• Work on equipment under load
5
Fatality GGV Mini Pit 8 February 2007
Horizontal brace bent upward
Main support structure bent
Main support structure bent
NOTE: This photo was discovered after the report done by the structural engineer
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Causes
Direct• Damaged/weakened structureUnderlying• Hazard awareness – not recognising potential• No protective barriers around legs of structure• Contractors safety system – poor• Contractor management• Incident reporting and investigation• Hand over between managers-protocol
7
Common trends identified during investigations
• Current Contractor Management Process had flaws
• Formal risk assessments not adequate• Health and safety systems of contractors not
adequate• Risk awareness and perception of Contractor
employees not good• Contractors understanding of Xstrata’s
requirements not good• Ownership of mine supervisors not adequate –
additional burden to administer the Pack documentation
8
Contractors Academy Established - December 2007
• An IT program was developed.• Change Management was conducted.• Required documents were reviewed.• The process was defined.• The Academy was staffed.• Pilot program initiated• Schedule of implementation compiled
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Process – Vendor Manager
Vendor process
Pre-qualification questionaire
Vendor application
Assessment and Vendor Approval (GM
to approve)
Enter into 2-3 year contract with Vendor
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Roles and responsibilities Vendor Manager
• Deal with Vendor application
• In conjunction with Academy assess Vendors
• Approve vendors for Xstrata
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Roles and responsibilities Mine Official/ Contractor owner
• Adhere to tender process• Provide a clear scope of work• Evaluate risk assessment with contractor manager• Provide Academy with a list of Contractor Employees,
equipment and vehicles to be used in case of existing contractors
• Provide Academy with an “Engagement File” of Contractor in the case of new contractors
• Manage contractor in terms of legal compliance as well as Xstrata requirements
• Evaluate and manage contractors “Working File” on a weekly basis
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Roles and responsibilities Academy
• Load HR data onto data base and keep employee files• Arrange and control equipment and vehicle inspections• Compile “Contractors Pack”• Assess risk assessments and evaluate adequacy of
Safety system• Assess Contractor Managers legal knowledge/Coach• Assist and compile with Contractors “Working File” –
safety work file• Assist mine supervisors/HOD’s with the management of
contractors• Audit implementation of Contractor Management
Procedure through out Xstrata Coal SA
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Clustering of Contractor
Maintenance & Repairs Electrical Work Construction / Civil
Cleaning/Painting Sandblasting
Security Conveyor Management
General labour Mining operations Sampling/Sanitation
Waste management Transporting Equipment Horticulture
Loading/Screening & Hauling
Reclaiming Transporting People
Other Rehab
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Training Matrix E LEC TR IC AL
U ND E RG RO U ND
P O LIC IE SG roup H SEC P olicyE nv ironm enta l Po licy
C om m unity Po licy
C O D E S O F PR A C TIC E - M andatoryM in im um S tandards of F itnessM edica l S urve illanceP revention and C om bating R ockfa lls / S lop eS tab ilityO ccupational H ea lth P rogram m e fo r N o iseO ccupational H ea lth P rogram m e on Persona l Exposure to A irborne Po llu tantsP revention of F lam m able G as / C oa l D ust Explos ions/Lam proom sTrackless M obile M achineryTherm al stress
C O D ES O F PR A C TIC E - R egulatoryP reventing Inundation o f W ater / G as - U nderground/In rushLockout / Energy Iso la tionB elt C onveyorsU G Substa tions
P R O CE DU R ES / STA N DA R D SEN G IN E E R IN G
Lockou t / Energy Iso la tion
Equi
pmen
t m
aint
enan
ce
D O C UM EN T
Elec
tric
al w
ork
Cab
le re
pairs
Mai
nten
ance
of
dust
scr
ubbe
rs
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Index Engagement File
VEHICLES 11
Contractor Mobile Equipment License Control sheet10
EQUIPMENT DETAIL9
LIST OF EMPLOYEES8
HIRA7
(Critical Task Inventory) (contractor supply)6
Baseline Risk Register5
Applicable Permits to perform High Risk work4
HAZARD IDENTIFICATION / EXPOSURE CHECKLIST3
SCOPE OF WORK (Contractor & Safety officer)2
COVERSHEET ENGAGEMENTBY OPERATION1N/ANOYESContractor Name
ENGAGEMENT FILE for CONTRACTOR INDEX
VEHICLES 11
Contractor Mobile Equipment License Control sheet10
EQUIPMENT DETAIL9
LIST OF EMPLOYEES8
HIRA7
(Critical Task Inventory) (contractor supply)6
Baseline Risk Register5
Applicable Permits to perform High Risk work4
HAZARD IDENTIFICATION / EXPOSURE CHECKLIST3
SCOPE OF WORK (Contractor & Safety officer)2
COVERSHEET ENGAGEMENTBY OPERATION1N/ANOYESContractor Name
ENGAGEMENT FILE for CONTRACTOR INDEX
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Auditing and Ranking-Once implemented
NO Process Deviations Remedial Actions
Score
1 Site Orientation
2 Schedule of PTO’s
3 Proof of PTO’s
4 Schedule of Planned Inspections
5 Proof of Inspections
6 Risk Conversant training
7 Proof of safety Meetings
8 Copies of pre-use
9 HIRA
10 Hazardous Chemicals, List & Training
11 PPE Register
12 Tool Inspection’s
13 Logbooks
14 Mini RA
15 Emergency drills
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Benefits to Xstrata
• Accurate contractor data base• Accurate Employee detail• Improved Risk Management documentation• Improved understanding of HSEC requirements
by Contractor Managers – Coaching• Cluster specific training/induction• Reduction in the delays of engaging employees• Reduction in admin – one Pack for Xstrata with
Engagement and working files per operation• One common message from Xstrata