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Safety Manager to Business Partner –

A Paradigm Shift1111thth Sept 2015 Sept 2015

NIRUPAM MUKHERJEEGlobal Safety Director – Engineering and ConstructionGlobal Safety Director – Engineering and Construction

PRAXAIR INC.

26F. KERRY PARKSIDE

1155 FANGDIAN ROAD

PUDONG. SHANGHAI-201204

[email protected]

Electrical Engineer and PG in Safety Engineering with 19 years of

diversified Safety Management experience in large scale green field,

industrial, transportation, infrastructure construction project. Gas

and air separation plants, process safety. Heavy engineering work

shops etc. Founder Member and Membership Chair ASSE India

Chapter. International Practice Specialty Liaison for India.

ObjectivesObjectives

Challanging the OBVIOUS

The primary objective of this research is to verify and revisit a few popular beliefs

• Safety Managers are responsible to ENFORCE Safety rules

• Following STRICT Safety rules ONLY can help prevent accidents

• Safety personnel slows down work, adds cost and make tasks difficult

• Safety is the only business they understand

Does these age-old paradigms still hold good?

What does the world expect from us (Safety Managers)?

Background Background –– Evolution of modern safety Evolution of modern safety phylosophyphylosophy

Most popular theories

Safety professionals have used some of the most successful and time tested

theories like

• The ‘Ice-Berg’ theory – Direct and Indirect cost of an accident

• Popular Safety catchy – ‘Safety First - Safety Must’

What we learnt and taught – Why follow Safety Rules?

Challenge Challenge –– Common BeliefCommon Belief

BUT, what did not change ?

A strong belief that - Following Safety rules will

• Make work slow

• Require more people

• Need detailed set-up. Hence, more materials, more cost

• Thus, a direct hit to the bottom-line

Result Result –– Diminishing Effect Diminishing Effect

• Growing apathy

• Increasing violation, At risk behavior

• Stressed relation between employees, client - contractor

• Complain – Safety affecting progress

Management Action

- More Enforcement

- Safety Monitoring

- Safety policing

Evolution of ‘Evolution of ‘Mr.SafetyMr.Safety CoPCoP’’

Changed role of a ‘Safety Engineer’

• Workers are SCARED – There Comes the ‘Safety Police’

• Accountable to - STOP unsafe conditions or behaviors

• Always in the field – WATCHING !!

• Recognition α Degree of ‘FEAR’ you generate• Recognition α Degree of ‘FEAR’ you generate

Result : ISOLATION at work

Mr.SafetyMr.Safety Cop Cop -- Desperate for a ChangeDesperate for a Change

Conditioned to play the role of a SAFETY COP needed to break free from the pre-

established image.

New Competencies needed –New Competencies needed –

• Positive attitude – Ready to help approach

• Effective Communication

• Most Importantly – Skill to work out easy solutions

• Awareness outside the world of Safety – How Business works?

First Step First Step ––> Business Partner> Business Partner

STEP CHANGE STEP CHANGE –– Not an easy task !Not an easy task !

• Mind set, habits were difficult to change

• Acceptance of Mr. Safety Cop in a different role was still difficult to accept

• No Trial and Error will be entertained

• A concrete proposal with measurable results was necessary• A concrete proposal with measurable results was necessary

• Knowledge / awareness about the overall business – Very Important

Example 1 Example 1 –– Game ChangerGame Changer

Management of Power cords in a Civil construction site

A CASE STUDY

Case 1Case 1

Management of Power cords in a Civil work site

Please see notes section for the description

Case 1Case 1

Proposed solution

Case 1 Case 1

Advantages:

• Safer – No sagging. More permanent set up. No energized work. No

incidents

• Reduction of approximately 150 meters of power cables : Cost reduction

• Easy cord management: No further handling, changing, replacement of

cordscords

• Reduced manual effort

• Reduction in time wastage

More ExamplesMore Examples

CASE STUDY II – Scaffolding work

CASE STUDY III – Materials HandlingCASE STUDY III – Materials Handling

CASE STUDY IV – Girder fabrication

Case II Case II –– Cooling Tower painting Cooling Tower painting


Work requirement - Problem

• The structures of the cooling tower were to be painted with anti-corrosive paint.

• Erect scaffold all around the equipment and manually and apply the paint.

• Require 20 scaffolders for 30 days to erect and dismantle the scaffold

• Additional field supervisors

• Significant amount of scaffolding materials

• Significant risk due to elevated scaffold work / fall hazard

• To meet demand, hire local workers

• Not enough time for detailed safety orientation, screening and onboarding


New approach - Solution

• Use two boom-lifts, each with two painters to apply the paint instead of erecting

scaffold for the task

Simple Change – Great benefits

• Savings of nearly 4000 man-hours

• Reduction of 3 supervisors• Reduction of 3 supervisors

• Substantial reduction of risk – 20 workers performing elevated work, scaffold

erection, dismantling

• No hiring of scaffold materials

• Most importantly - Reduction of more than 30 days schedule

Case III Case III –– Materials HandlingMaterials Handling

Challenges

Problem

• Manual transportation of materials from job site to warehouse (500 m away)

• Routine task by multiple workers – to and from the warehouse

• Risk of fall, strenuous task, wastage of man-power, time – low productivity

Challenges

• Hiring mechanized equipment / truck is expensive

• Materials are required in small quantity to maintain an

uncluttered site and good housekeeping.

• Extra materials are required to be returned to the

warehouse after each day’s work.


Solution

• Arrange manual material carts with large wheels.

• Deploy two workers per trolley to shift materials


Benefits

• A cart can carry approx. 15 times than a single person. Say, 5 cart trips = 75

individual trips --To & fro travelling time + waiting time - approx. 30 mins.

• Say 1 cart does 5 trips – Approximately 35 man-hours saved / day

• Nearly 650 man hours saving / month (35 x 26)

• Last but not the least, the safety concern could be eliminated

Happy contractor, happy workers – Safe work

Case IV Case IV –– FabricationFabrication

Work procedure challanges

• Fabrication of ‘I’ section steel girders - 18 meters (span) x 2.5 meters (tall)

• Hundreds of 100 mm (4 inches) steel anchor bolts to be welded on the top flange

• Positioning on a 300 mm (12 inches) wide flange at 2.5 meters height and

continuously performs welding was a real challenge & risky

• Fall arrestor / harness / lifeline was of no help

Proposed work procedure

• Build scaffold on both side of the flange at the

same level

• Procedure was Safe, but was slow, expensive �

Less productive


Final solution

• ‘Problem’ is due to elevated work – can it be removed altogether?

• Position the ‘I’ girder slant instead of vertical as shown in the sketch

• A foreman added an ides to use a template to position the bolts easily

• This new solution and team work paid off


Advantages

- Much safer than the earlier work methods

- Approximately 2000 man hours saving due to elimination of scaffolding

construction and removal every month.

- Complete elimination of elevated work – Hence the entire risk of fall

- ‘I’ girder delivery schedule was more than 20 % quicker

- Great quality – No misalignment, better weld quality, less repair

- Welder’s work position improvement – Less fatigue, health hazards

Final VerdictFinal Verdict

A positive Change

• A new and fresh image for Mr. SAFETY-COP

• New leadership position within the team

• Perspective of SAFETY MANGEMENT underwent a BIG change

• Job-Satisfaction – Respect – Recognition

A complete over-haul of the age-old safety culture took place. Safety viewed as an

‘ESSENTIAL’ element than ‘ADD-ON’

SAFETY SAVES for the first time was interpreted correctly !!

Safety IS DIRECTLY αααα to Profitability and Productivity

The Next Gen Safety EngineersThe Next Gen Safety Engineers

The ‘next-gen’ safety professionals will not only be recognized by the new

technologies and modern equipment they will adapt, but also the creativity

and innovation with which they will offer practical solutions.

World is waiting for them –

The ‘Generation Next’ safety leaders!

THANK YOUTHANK YOU

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