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AN INTRODUCTION TOZero Injury Program

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Safe Behavior

Is safe behavior an occupational necessity?

Can safe behavior be a philosophy of life?

Is safety only at work place?

Don’t I want my son to drive safely & reach home every day?

Safe Behavior = Safety Assurance

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Principles of BBS

Behavior is the cause of accidentsConsequence motivate behaviorWhat gets measured, gets doneFeedback is essential to improvementQuality is built early in the processConversations change organizations

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BBS vs. Zero Injury

Zero Injury is the GOAL

BBS is the path to reach the GOAL

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Fundamental Belief of Zero Injury

I believe that all injuries are avoidable and can be prevented

If you do not believe, you cannot implement zero injury program

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DuPont Research found that . . .

30,000 Hazards(Unsafe Acts & Conditions)

3,000 Near Miss / First Aid

300 Non LTAs

30 LTAs

1Fatal

Eliminate

Avoid

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Fundamental Belief . . .

I believe that all injuries are avoidable and can be prevented

Is it possible to avoid injuries totally?

YES !

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How to Implement BBS ?

7 Steps Process

1. Identify Unsafe Acts. Make a list of safe acts2. Audit Unsafe Acts & Conditions. Report3. Measure no. of safe / unsafe acts. 4. Set Improvement Goals. Identify actions to achieve the goals. Implement Actions

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How to Implement BBS ?

7 Steps Process

5. Monitor actions implementation & trends of Unsafe Acts & conditions6. Continually improve performance7. Recognize safe performers

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1. Audit & Identify Unsafe Acts & Conditions

What do we do in Zero Injury . . .

2. Rectify & report the same3. Monitor the elimination of the identified acts & conditions.4. Monitor the number of unsafe acts & conditions. Is it decreasing or same?

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1. Fix a time of the day when you are free from high pressure activity. After lunch?

How to audit unsafe acts, conditions?

2. Go to one specific location of your plant where activity is going on.3. Observe the activity and the location for 10 min.4. Note down what unsafe acts were done? What unsafe conditions existed?

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5. Write your observations in the prescribed format

How to audit unsafe acts, conditions?

6. Stop Unsafe acts immediately. Prescribe safe way7. Immediately correct the unsafe condition. Some corrections could be temporary. Make it permanent8. Monitor reasons for recurrence of unsafe acts & conditions

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Any knowledgeable person. At least team members of your Zero Injury team. Why?

Who does the audit?

Greater employee participation

is critical for Zero Injury culture

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Identify the unsafe acts & unsafe conditions in the card room

An Exercise . . .

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1. Non Use of helmet while driving 2 wheeler

Examples of Unsafe Acts

2. Non use of PPEs3. Not holding rails while climbing4. Ladder not tied securely5. Unauthorized use of equipment6. Use of defective tools, wrong use

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7. After RM charging, no arranging drums

Examples of Unsafe Acts

8. Bypassing safety devices. Short cuts.9. Riding hazardous equipment10. Stand at wrong place11. Unauthorized use of equipment12. Failure to signal while driving

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1. Absence of guards around moving eqpt.

Examples of Unsafe Conditions

2. Fire & explosion hazards3. Poor ventilation4. High noise. Low lighting5. Absence of sign boards6. Slippery floor. Missing step in stairs.

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1. Rigorous Self Audits in plants

4 Pillars of Atul’s Zero Injury

2. Use of PPEs

3. Hazard identification through Engineering Work Request4. Training to all on accident prevention

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Do you receive my monthly report?

Your Feedback . . .

Can you tell me what is the total LTA so far?

What are critical areas for improvement I have mentioned?

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How is Zero Injury progressing in your plant?

Your Difficulties . . .

What are the issues being faced by you?

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When you go back to your plant, what will you do specifically for Zero Injury Program?

Your Commitment . . .

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We wish all of you attain Zero Injury both at plants and at home

Wishing you all . . .

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Let us recall what we learnt last 2 days

SHE Training Summary

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1. Atul’s Core Values on SHE• SHE is a line function• Profit, Production, Quality & SHE are

equals

SHE Training Summary

2. Atul’s SHE Policies

3. MSDS & its application

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4. Legal obligations & your role

SHE Training Summary

5. Emergency preparedness

6. Workplace hazard assessment & control

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7. Behavior Based Safety• “at risk” behavior = Accidents• Safe behavior = Safety Assurance

SHE Training Summary

9. Techniques for SHE Improvements

8. Zero Injury Program