ehs first - campbell · pdf fileehs first™ the starting point management ... dilemma:...
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The Business Case for
EHS FIRST
as Applied to Alcan’s
New Joint Venture Smelter
in Ningxia, China
Simon Laddychuk
Vice President EHS FIRST
and Sustainability, Alcan Inc.
Nathalie Fortin
Manager-Environment, EHS FIRST
Alcan Inc.
Chantal Westgate, Tom Kosatsky
McGill University
™
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Alcan at a Glance
Founded in 1902
Today:
A global leader in bauxite, alumina and aluminum
A top-ranked provider of engineered solutions and specialty/flexible packaging
US$23.6 billion (2006)
Dow Jones Sustainability World Index since 2003
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Global Presence
65,000 employees
61 countries and regions
EHS FIRST Policy in 11 languages
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Alcan
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Alcan
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Alcan Process Map with Key Issues
Energy, Water, AuM, Waste, Health, Safety and Employee Engagement
Biodiversity
Bauxite
residue,
PM, Haz.
Energy
Energy
PAH
Energy, So2,
GHG, PM,
SPL. PFC,
Haz. Energy
VOC, OPI, Product
Stewardship
OPI, Product
Stewardship, Mobile
Equip.
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EHS FIRST
The Case for Why?
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84% Reduction in Recordable Cases
87% Reduction in Lost Time Cases Since 2001
2001 2002 2003 2004 2005 2006 2007
Rate 5.59 5.04 3.30 1.95 1.51 1.16 0.79
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Rapid Growth: Distinct Challenges
2006
algroup Combination
October 2000
April 2003
VAW Acquisition
Pechiney Acquisition
December 2003
January 2005
Novelis Spin-off
5
25
Net operating revenues
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EHS FIRST
Why Common Foundation?
Common language to drive continual improvement
The leadership practices to deliver excellence as well as the technical knowledge
Leverage common processes and best practices where appropriate; invent once not (n) times
Leverage learning across entire organization and move to best practices quickly
Ability to move people more easily within the organization
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A World of Benefits
Reduced accidents, occupational illnesses and environmental incidents
Greater employee health, morale and well-being
- Reduced absenteeism
Increased productivity and profitability
Enhanced reputation, market share and stakeholder relationships
Reduced liabilities and insurance premiums
Satisfy investor criteria for EHS and improve
access to capital
Stimulate development and sharing of EHS solutions and best practices
Contribute to our corporate governing objective of Maximizing Value
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The Results Status as End of 2006
Milestones 2006 best ever performance in safety for all metrics and
in all regions of the world
30M US$ compensation costs avoided through H&S incident rate reduction 2001-2005
BG, BS, BU President & Sr. Leaders participation in serious event communications, follow up and other EHS FIRST activities
2003-2006 formally trained 15,000 employees in Alcan global training programs
20% of CI Black Belt projects are EHS FIRST projects
Since 1990, reduced emissions of 3.5M tonnes of CO2 (equiv)
All Alcan sites certified ISO14001 and OHSAS 18001
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Awards 2006-2007
One of Fortune
Magazine’s
2006 MOST
ADMIRED
COMPANIES
In top three companies
overall and the leading
company in the metals
and mining industry —
global climate change 2006 International Stevie®
Award for BEST
CORPORATE SOCIAL
RESPONSIBILITY
PROGRAM
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How We Created EHS FIRST
Call to Action
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Benchmark
Company 1 Company 2 Company 2
Principal Audience
Executives to Site Managers
This manual:
Establishes a common foundation and framework for managing EHS in line with values, policies and objectives
Spells out key EHS requirements (why and what)
- Make links with the how
Prescribes requirements for integration of EHS with organizational processes
Sets expected core competencies, behaviours, roles and responsibilities regarding EHS (focus Executive to Site Manager)
Establishes EHS expectations, deliverables and accountability
Serves as an educational and developmental tool
EHS FIRST — Building on Our Foundation
of EHS Capabilities
Benchmark
Company 1 Company 2 Company 2
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What is EHS FIRST?
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Proven Management System to Create
Business Sustainability
AIMS — Alcan’s Integrated Management System four components EHS FIRST, CI, VBM, APA
EHS FIRST Steadily improving EHS performance
CI — Accelerating CI benefits
VBM guiding methodology
New people component — Alcan’s people advantage
Integrating environmental, social and economic externalities to understand risk and develop new opportunities
Business Sustainability Maximize value for our stakeholders
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EHS FIRST — More Than a Management System
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EHS FIRST Knowledge Codification
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EHS FIRST™ The Starting Point
Management
What we do!
Engages the mind
Gets the right things done
Based on “transactions”
Produces product
Leadership
How we do it!
Engages the heart
Gets things done the right way
Based on commitment to values
Produces change
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EHS FIRST People in Action
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EHS FIRST People in Action
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EHS FIRST Training
Advanced simulation techniques and role play used in training for Executives to shop floor
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EHS FIRST Training
Advanced simulation techniques and role play used in training for Executives to shop floor
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EHS FIRST™: The Business Integrator
Facilitates and accelerates integration during M&As
- Powerful unifying force
- Rallies employees around shared EHS values, objectives and goals
Apply same high standards everywhere
Learn from each other and build respect
Pechiney success story in EHS
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The Case
Yang Xiaoping was a wagon pusher working for
a contractor at the Alcan smelting complex in Ningxia,
China. Before the creation of the joint venture,
environment, health and safety (EHS) practices at
the facility were poor and record-keeping was virtually
non-existent. Alcan’s EHS FIRST system was
implemented with the initiation of the joint venture:
important changes in work practices and improvements
in health, safety and environmental indicators followed
soon after. However, on January 12, 2006, Mr. Xiaoping
suffered a fatal injury when he was crushed between two
loaded wagons being pushed by hand into the combined
pedestrian and vehicular entrance of the complex.
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Case Objectives
Change management: systematic process
The challenge of international joint ventures: ethnocentrism, geocentricism
- Contractor management
- Cost and benefits of managing stakeholders’ expectations
Linkage between EHS and business performance: EHS FIRST in a complex internal and external environment
Approach to addressing both short term business priorities and the longer term goals of EHS FIRST
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Alcan Business Environment
Business strategy: “Maximizing Value”
Long term decline in the real price of aluminium
Pressure to improve return on investment
Competition for other materials such as plastics and steel
Changing demand of global customers
China: aluminum companies adding smelting capacity: could lead to drop in aluminum price
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Location of Ningxia Smelter
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Alcan Ningxia Joint Venture
Alcan Ningxia joint venture: inception 2004
Investment of $150 million for 50% participation in an existing pre-bake smelter
Strategic business move to enhance Alcan’s position in the world’s fastest growing economy
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Ningxia Smelter
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Alcan’s Joint Venture, January 2004
1,300 employees. Young workforce.
At inception, low efficiency (as measured by aluminum produced/electricity consumed)
Typical jobs in the smelter:
Pot room attendant
- Pot tending
- Pot lining
- Crucible transporters
Crane and vehicle drivers
Anode operator
Casting operators
Electrical technician
Mechanical technician
Pipe fitter
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Ningxia Work Organizational Chart
Deputy CEO
Shengyu He CEO Assistant
Amanda Sun
HR Manager
Haibin Liu
Sales and
Marketing
Manager
Guangdong Pan
Procurement
Manager
Dianlin Chen
Imp. Exp. &. RM
Procurement
Manager
George Zhang
Anode Manager
Weiguo Wu
Engineering Manager
Li Guochang
Health Supervisor
Tian Miao
Environment
Supervisor
Xiaping Li
Safety Supervisor
Guy Meng
Finance
Deputy CFO
Zhang Nan
IT Manager
Shuling Li
CI Manager
Xuewei Liu
Logistic Center
Manager:
Yanwen Li
Administration
Supervisor
Winnie Wang
CFO
Ian Briggs
Commercial
Director
Foster Lee
EHS Manager
Liu Liping
CTO
Claude Tousignant
HR Director
Morris Mu
Chief Executive Officer
Alexandre Gomes
Auxiliary/Utilities
Manager
Hongbing Mu
ReductionManager
Qinghua Zhou
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Ningxia — Environmental Aspects
Environmental aspects related to smelting:
Energy use and GHG emissions
Air emissions
- PAH
- SO2
- Fluorides
Water use (in an arid zone)
Wastewater disposal
Waste
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Health issues related to smelting:
Respiratory exposures to PAH, SO2
and hydro-fluoric acid
Heat stress
Noise from pneumatic pot operations, and anode production
Asbestos exposure
Skin exposure to PAH
Ergonomics of difficult postures, heavy lifting
Ningxia — Health Aspects
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Safety issues related to smelting:
Mobile equipment and pedestrian safety
Falls from heights
Confined space
Burns, explosions
Equipment failure
Ningxia — Safety Issues
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Joint Venture Leadership
Leadership effectiveness — Ningxia plant manager
Global leadership:
Global mindset
Tolerate high levels of ambiguity
Cultural adaptability: emotional connection to people from different cultures
Transformational leadership:
Provided employees with a new vision that instilled true commitment
Reference: Organizational Behaviour, Pearson, 322-323
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Alcan: Learning Organisation
EHS FIRST: Geocentric
- “To be a recognized leader of environment, health and safety excellence in everything we do and everywhere we operate”.
- Best practices from Alcan, ISO 14001, OHSAS
- Based on: “Plan – Do – Check – Act” methodology
Leadership: Ethnocentric
Staffing: Polycentric
Dilemma: transferability of best practices?
Leadership, EHS FIRST and Staffing in Ningxia
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Dilemma: transferability of best practices?
EHS FIRST as a driver of integration
Assumption of universality
Cultural differences: Confucian dynamism
Countries differ in their readiness to adapt or adopt foreign model or to manifest NIH syndrome
Reference: Managing Across Cultures 2003 109-114
Leadership, EHS FIRST and Staffing in Ningxia
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Joint Venture as an EHS Challenge
No EHS culture/values before joint venture
Lack of environment management and monitoring system
Lack of health management system: No information on past injuries
Lack of basic personal protection equipment:
- Safety glasses and proper respiratory protection
- Lack of plant air conditioning or cool water in the workshop
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Alcan Joint Venture
Benefits of joint venture
Global reputation, brand image
Leader in corporate citizenship
Environmental and social sustainability
Quality
Decrease injuries
Developing employee’s capabilities
Increasing efficiency
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Issues to address going into the joint venture
Chinese culture
Language: high vs. low context culture
Particularist vs. universalist
Employees level of skills
Higher tolerance to risk
Joint venture partners’ values are profitability and low cost
Managing contractors
Line managers considered EHS a “safety department job”
Reference: Managing across cultures, 2003, 109-114
Dilemma: How can Alcan succeed in installing an EHS culture as part of a joint venture in Ningxia?
Ningxia Joint Venture
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Dilemma: How can Alcan succeed in installing an EHS culture as part of a joint venture in Ningxia?
Scanning the environment
Refreeze
Assess current situation
recognize gap Set objectives
Change tactics
Unfreeze behaviors Change
Evaluate, make necessary
adjustments
Reference: The New Managing Human Resources, McGill University, 2004
Ningxia Joint Venture
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Dilemma: How can Alcan succeed in installing an EHS culture as part of a joint venture in Ningxia?
Can be incremental, radical, planned
Driving and resisting forces of change
Systematic approach to change
Employee involvement
Ningxia Joint Venture
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Some actions:
Training 59,356 person-hours of EHS in 2004 and 72,394 hours in 2005 or 4% of training time per employee.
Improvement of furnace operations: elimination of frequent fires
Distribution of PPE and training in its use
Working on a Behavioural Accident Prevention Process (BAPP)
Ningxia Joint Venture
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Competing priorities:
Productivity, quality, operating costs, profitability and EHS needs, lack of strong technical employees since Ningxia is in a remote location
Dilemma: given these competing priorities, to what degree can EHS be FIRST?
Alcan Business Environment
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How can EHS be given competing business priorities?
Having a vision
Line management fonction
EHS FIRST in strategic planning and decision making
EHS is a leadership competency: integrated into Alcan’s Performance and Career Management
Each employee given specific EHS objectives
Compensation and recognition based on EHS performance
Alcan Business Environment
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Competing Priorities
How can EHS be given competing priorities?
The belief that quality, productivity, profitability and EHS excellence are mutually supportive objectives, and align behaviours around that belief.
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Managing stakeholders’ expectations:
Employees, shareholders, customers
Public interests’ groups, union, government
Contractors, Maison Alcan (due diligence requirement), communities
Continuous improvement in health and safety not totally in management’s hands
Dilemma: cost and benefits of managing stakeholders’ expectations?
Competing Priorities
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Dilemma: cost and benefits of managing stakeholders’ expectations?
Reduction in worker’s compensation costs
Reduction in employee’s grievance
Reduction of days lost
Reduction of insurance premium
Saving in productivity due to reduction of lost time incident
Reduction of environmental footprint with improvement of resources use and reduction of emissions
Competing Priorities
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Contractors Workers
Contractors workers: 30% at the time of joint venture
Lack of training, low educational level, local culture of giving “hard manual work” to contractors, high turnover rate, particularly for special projects such as construction
Above factors increased risk of accidents to themselves and others
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Contractors Workers
Contractors workers:
Contractor employees are not aware of plant routines, safety rules or emergency procedures
Contract employees often lack skills and experience due to frequent job rotation and turnover
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The Contractor Dilemma
Rates of severe workplace injuries are more common in contractors than regular employees at aluminum smelters. However, overall injury rates appear similar (could this be due to reporting bias?)*
Using contractor employees provides flexibility and lower costs
Suggest an optimal contacting policy in a smelter
where EHS is FIRST
*Reference: The aluminum industry in Brazil, M.Arrruda
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Suggest an optimal contacting policy in a smelter where EHS is FIRST:
Contractor selection should be based on an evaluation of their past EHS performance and capabilities
EHS rules and expectations must be communicated to the contractor
Look at each contractor’s EHS performance: should be monitored and feedback reported to the contractor
Employee training
Requirement to conduct hazard identification and risk assessment prior to beginning work
The Contractor Dilemma
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Ningxia Actions and Results
Call to action: inciting employees to report incidents
Measurement of EHS FIRST performance with EHS metrics
- Lagging: lost-time injury, worker’s compensation costs
- Leading indicators:
• Number of trained observers
• Numbers of safety observations carried out per week/month
• Percentage of safe behaviour, according to standard, for each observations
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Obtained ISO 14001 and OHSAS 18001 certification within 11 months
Physical changes made to the plant:
- Fencing the facility
- Redesigning entrances and corridors to keep pedestrians away from moving equipment
Started measuring gaseous fluoride emissions on the smelter roof with Alcan’s standards
GHG reduced to 66% from pre-JV levels
Ningxia Actions and Results
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Ningxia EHS FIRST Policy
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LTII Case Rate
Recordable Case Rate
2006 Highlights
Achieved 2,2 million hours without recordable accident in Feb 07, first ever in APMG history
3,2 million hours without lost time accident (April 07)
Strong employee-involvement BAPP initiative implementation started
0.54
0.20
0.000.00
0.50
1.00
2005 2006 2007 Q1
1.08
0.47
0.20
0.00
0.50
1.00
1.50
2.00
2005 2006 2007 ytd
Ningxia Actions and Results
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