the safe work cycle: connecting the dots for a safe … · the safe work cycle: connecting the dots...
TRANSCRIPT
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The Safe Work Cycle: Connecting the Dots for a Safe Workplace
East Kentucky Power’s Safety Evolution
From Git-R-Done to Our Brother’s Keeper
Presented to Rapid Fossil Group
25th Annual Rapid Conference
May 17th, 2016
Presented by: Steve Dobson & Mark Hounshell
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Our Culture & The Industry Culture
• Keep the light’s on
• Reliability is paramount
• No pain, no gain
• Real men don’t fatigue
Monty Python’s Black Knight
“Never Give Up.”
“It’s just a flesh wound!”
“…men were men and cars were cars.
Nothing like these plastic and tinfoil
Models we have today! ”
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EKPC’s Safety Evolution
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EKPC Safety - A Need for Change
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Interim CEO & Safety First!
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After a long term CEO retired we hired an Interim
CEO who preached safety first.
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The New CEO “The Hammer”
• He instituted his own tough love approach
• He now refers to it as his Hammer
approach
• Stats improved, but something was wrong
• A survey revealed the culture and attitudes
were not changing
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“Forged” Results
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The Reality Check
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• Safety did not improve significantly
• Realization that something was wrong
• Events were underground – Occurrences
were not being reported
• Cultural perception that safety was a
buzzword but production still came first
• Recognition that a new approach was
needed
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CEO Apology
• CEO personally addressed all workgroups and
acknowledged that his approach was wrong
• VPs conducted meetings with their work groups
to talk frankly about the survey results
• The trust level of executive staff rose and in turn
trust for all Management
• Employees immediately began reporting
incidents more frequently
• And then … The Near Miss Miracle was a
catalyst for change
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A New Beginning
• 2011 - New direction and approach
• Hired DuPont
• Formed safety teams for integrated effort
• Established Sr. Executive safety
committee & safety team sponsorship
• Embarked on establishing a new culture
through a new method
• And then, the miracle happened
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An EKPC Safety Stan Down Video will be shown here.
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What Now?
• Investigation into why static failed.
• Communications about how to act around
downed lines, etc. are posted on EKP
Central
• Hazard recognition will be re-emphasized
at all locations
• Communications between the Plants and
Power Delivery will be further examined
• Safety Stand Down where employee
involved will be the featured speaker12
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The Buy-In
• Management’s handling of the EKPC
Miracle was a home-run
• Employees embraced the “Brother’s
Keeper” safety culture
• Safety gained grassroots support
• Safety teams made an immediate and
significant impact
• The culture has radially changed over the
course of 3-5 years 13
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Key Elements Behind the Change
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Central Safety Committee
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EKPC Safety Teams – An Integrated Effort
• Incident Investigation
• Rules and Procedures
– JHA
– Management of Change
– Human Performance
• Contractor Safety
• Communications
• Safety Observations
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Small Strides Resulted
in Cultural Change
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Willful or negligent violations of EKPC’s
Cardinal Safety Rules could result in a
serious injury.
Violation of these rules may, upon
completion of an investigation, result in
disciplinary action up to and including
termination.
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We’re Making Progress
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But - Don’t Get Hung Up On Numbers
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TRIR previous average = 7.4
TRIR for last five years = 2.00
TRIR for 2015 = 1.27
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Which Would You Rather Be?
Company XYZ
100 Employees
TRIR = 4.00
DART = 0.00
LTR = 0.00
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Company ABC
100 Employee
TRIR = 5.00
DART = 2.00
LTR = 2.00
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Numbers Can Be Misleading
Company ABC
100 Employee
Five Incidents
• Spider bite
• Wasp sting
• Tick Bite
• Slip and fall (2)
The spider bite and tick bite both
became slightly infected causing the
employees to both lose one day of
work, that resulted in a DART and LT
Rate of 2.00
Company XYZ
100 Employees
Four Incidents
• 2 electrocutions (both fatalities)
• 2 Falls from height (both fatalities)
Fatalities are not recorded as days
away or lost time so the DART and
LT Rate are both zero.
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Keys for Building a Sustainable Safety Program
Executive Management Support
Building Trust
Reinforcing that Safety is a Line Management Responsibility
Engaging Employees26
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The JHA
An Important Safety Tool
& Linchpin of the “Safe Work Cycle”
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What is a Job Hazard Analysis?
• A technique that focuses on job tasks as a way to
identify hazards before they occur
• Focuses on relationships between worker, task,
tools and work environment
• Identifying hazards and eliminating them or
controlling them as early as possible will help
prevent injuries and illnesses
• Goal is to identify uncontrolled hazards and take
steps to eliminate or reduce them to an acceptable
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JHA Core Focus
Specifically, this JHA procedure and all safety efforts shall
focus on six core fundamentals of safety by ensuring that all
employees:
– Possess the required skills to perform the job
– Use the right tool for the job
– Wear appropriate personal protective equipment
– Conduct required Job Briefings
– Stop work if there is a safety concern or question
– Report all near misses
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What are the OSHA Requirements?
– OSHA 3071
– OSHA 1910.269 (a) (b) (c) – Electric Utilities
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Rules & Procedures Team Action
• The EKPC Safety Rules & Procedures Team:
– Identified EKPC need for JHA documentation
– Incorporated JHA procedure need with others to be written
– Researched JHA programs, processes, and templates
– Wrote JHA Procedure & Supporting Documents
• JHA Form
• JHA Tool Kit to assist in assessing needs and writing
JHAs
– Gathered information from operating groups
• Inventory of top 10 most dangerous jobs & work
environments
• Top 10 jobs eligible for JHAs based on hazards and risks
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EKPC State At Beginning of Process
– Safety hazards & preventive measures are currently being
addressed via job briefings and in specific work procedures
– EKPC has relied on experienced, knowledgeable
employees, work procedures and job briefings to address
safety concerns and measures
– “Tribal knowledge” is a factor
– Documented JHAs will support OSHA compliance
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EKPC Initial Concerns
– Lack of formal documentation
• Assurance, consistency, OSHA
– Reliance on “Tribal Knowledge”
• EKPC’s changing workforce
– Industry Attributes
– Type of Work & Working Environment
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Why is a Job Hazard Analysis Important?
– Many workers are injured or killed at the workplace daily in
the U.S.
– Safety and health can add value to your business, your job
& your life
– Workplace injuries and illnesses can be prevented by
looking at workplace operations, establishing proper job
procedures, and ensuring all employees are trained
properly
– One of the best ways to determine & establish proper work
procedures is to conduct JHAs
– JHAs are a one component of the large commitment of a
safety & health management system 34
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Hazard Control Measures
The Job Hazard Analysis shall be used as a guide to determine
actions necessary to eliminate or minimize hazards
Associated with the job.
– For each Hazard identified, list the Hazard Control Measures
to be taken to protect the worker from the Hazard
– Hazard Control Measures according to OSHA 3071 include:
• Engineering Controls (i.e. design safety measures)
• Administrative Controls (i.e. written procedures)
• Personal Protection Equipment
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What is the Value of a Job Hazard Analysis?
• Supervisors can use findings of JHAs to eliminate potential hazards
• Likely results are:
• Fewer worker injuries
• Safer, more effective work methods
• Reduced workers compensation costs
• Increased productivity
• JHAs can be a valuable tool for training employees in the steps
required to perform their jobs safely
– For JHAs to be effective, management must demonstrate a
commitment to safety & follow through to correct any uncontrolled
hazards identified
– Failure to follow through will damage credibility & may discourage
employees from exposing dangerous conditions
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What Jobs are Appropriate for JHAs?
– Jobs with highest injury or illness rates
– Jobs with potential to cause severe or disabling injuries or
illness, even if there is no history of previous accidents
– Jobs in which one simple human error could lead to a
severe accident or injury
– Jobs that are new to the operation or have undergone
changes in process or procedures
– Jobs complex enough to require written instructions
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Where Do I Begin?
– Involve your employees
• Unique understanding of job, valuable for finding
hazards
• Minimizes oversights, ensures quality analysis
• Ensures employee “buy-in” and ownership
– Review accident history
• History of accidents & illnesses, losses, & near misses
indicate where existing hazard controls (if any) may be
inadequate
– Conduct preliminary job review
• Discuss hazards that employees know exists in current
work or surroundings, brainstorm for ideas to eliminate
or control them
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Where Do I Begin (continued)
– List, rank and set priorities for hazardous jobs
• List jobs with hazards that present unacceptable risks based
on those most likely to occur and with most severe
consequences
– Outline job steps or tasks
• Watch employee perform job
• List each step as the worker takes it
• Enough information to describe job, but not overly detailed
• Not so long or broad as to lose basic steps
• Input from other workers who have performed jobs
• Review steps with employee to avert omissions
• Emphasize that analysis is of job, not employee performance
• Include employee in all phases of analysis
– From reviewing job steps & procedures to discussing
uncontrolled hazards & recommended solutions
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How Do I Identify Workplace Hazards?
JHAs are an exercise in detective work with the goal of
discovering:
– What can go wrong?
– What are the consequences?
– How could it arise?
– What are the other contributing factors?
– How likely is it that the hazard will occur?
Document answers to these questions in a consistent manner.
This will help ensure that efforts to eliminate the hazard &
Implement hazard controls target the most important
contributors to the hazard
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Elements of Good Hazard Assessment Scenarios
Good hazard scenarios describe the following:
– Where it is happening (environment)?
– Who or what is it happening to (exposure)?
– What causes the hazard (trigger)?
– What are the potential consequences?
– What are the other contributing factors?
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A Risk Assessment Tool
Useful as a JHA Guideline
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JHA Form
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Warehouse Safety
• Cardinal Rules
• Safety Moments
• Job Procedures
• Job Briefings
• JHAs
• Safety Observations
• Safety Work Practices
• Forklift Inspection Log
• Safety Town Hall
Meetings
• Warehouse Audits
• Safety Work Practices
• Forklift Inspection Log
• Good Housekeeping
& Organization
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EKPC Materials JHAs
• General Forklift Operation
• Forklift - Handling Irregular Material
• Forklift – Material Put Away
• Securing & Releasing Delivery Vehicles
• Trailer Inspection
• Loading/Unloading Tractor Trailers
• Installing Steel Racking
• Working in Hazardous Weather Conditions
• Strapping/Unstrapping Pallets
• Handling Compressed Gas Cylinders45
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Forklift Safety
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Address the number one danger in your warehouse
Featured: An idea brought to Materials Management
by a new employee.
The Blue Spot safety light is being adopted in all
plants at the request of our CEO after a safety walk.
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Know Skill Limits & Tools
Don’t Exceed Them.
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EKPC warehouse employees avoid rigging and operating
equipment outside their expertise.
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Good Housekeeping, 5S, & Signage
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Good Housekeeping, Work & Storage
Practices Keep Everyone Safe
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Leadership Makes a Difference
in Life & Death
OTHERS EKPC
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Questions & Discussion
Safe by choice, not by chance & always go home safely.