Safety at Alcoa – Programs that Work

Oak Ridge Business Safety Forum

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December 11, 2013

Metrics – Lagging Indicators

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0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

2005 2006 2007 2008 2009 2010 2011 2012 2013

3.83

2.33 2.42

3.11

2.31

1.73

1.46 1.51

1.19

1.65

0.80

1.13

1.79 1.67

0.64 0.77

1.01

0.37

TR DART

Fatality Prevention Process

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Dept Safety Committees Review Topic and

Physically Verify LOP are in Place

Rigging Safety

Hazard – Dropped Load, body part crushed by load

Layers of Protection Hierarchy of

Controls

All personnel responsible for rigging loads must attend

rigging training

Administrative

Inspect all sling equipment before each use Administrative

Understand load capacity and select the right type of

rigging equipment (wire rope, chain etc.. .)and correct

capacity

Administrative

Determine the center of gravity of load and apply

rigging so each leg carries an equal share of the load

Administrative

Do not position hands and fingers between sling and

load or load and fixed object

Administrative

Do not stand or work in the VDZ Administrative

Use a spotter, hand signals or other means to clearly

communicate load movement

Administrative

Identify operator work zones (signs/paint floor) that

are clear of drop zone or flight path

Warning Device

Use hands free equipment (tagline, rods, hand holds

etc…) to guide load into place

Safety Device

Fatality Prevention/Incident Prevention

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Leadership Visibility AND Risk Recognition

Review All Items Monthly

with Lead Team

Lead Team Verifies

LOP

Lead Team Walk through

• Select Random Area

• HK, Compliance, HP

Observation

Observation Form

Davenport Works

Job Review Form

Fatality Prevention (Stop for Safety Campaign)

Designed to keep working safely in the forefront of

employees’ minds

Reinforce that it is okay to STOP and Seek Help in

unsafe situations or when you are unsure

Gives us the chance to recognize employees who

STOP – themselves or others

Learn from each other by sharing the lessons

learned from STOP situations with the entire

organization

Stop Criteria are pre-determined

performance modes, triggers,

conditions, or outcomes of

systems, processes or tasks

Relate Back to the Worst Credible

Thing That Could Happen

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Human Performance - Stop Criteria

Examples of Stop Criteria

Working in a Knowledge Base Mode.

Change from plan or process

Process goes outside of system

limitations

Any first time or infrequent tasks.

Working around stored energy source.

Use of fall protection.

Electrical Troubleshooting.

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Human Performance “Measured Integration”

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Human Performance – “Cascading System”

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EHS Planning

Overarching A3 Process

Business Case

Current Condition

Problems/Problem

Causes

Target Condition

Action Plan

Sub A3’s

Cascade to Dept A3

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Backup

Slides

Human Performance - Pre-Task Brief

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Human Performance - Pre-Task Brief

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GRP EHS Standards

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GRP EHS Standards

New to the Job

Outage Planning

Blue Light

Contractor

Safety Standardized skills checklist

Mentor/Mentee for every NTTJ

NTTJ/Supervisor ratio

Identification markers

Required initial HP training

Enhance vehicle visibility

Decrease vehicle/pedestrian interface

Pre-planning

Safety Plan

High risk observations

Critical items checklist

standard audits

Enhanced Contractor Program

Project leaders -8 hrs HP training

Standard audit expectations

Orientation requirements