The Basics in Delivering Zero Harm and Sustainability Barry Formosa

Transcription

1 Mt Arthur Coal Reflections and Lessons The Basics in Delivering Zero Harm and Sustainability Barry Formosa Vice President HSEC, Energy Coal March 2012

2 Recent Catastrophic Events Tesoro Refinery Explosion Gulf of Mexico Deepwater Horizon Oil Spill Upper Big Branch Mine Disaster Pike River Mine Disaster PG&E Pipeline Explosion Chilean Mine Collapse Barry Formosa, Vice President HSEC, Energy Coal, March Slide 2

3 Common Lessons from Catastrophes Management Drew Comfort from Low Injury Rates Reward Mechanisms Linked to Low Injuries No Effective Focus on Catastrophic or Fatal Risk Low Incident Reporting Culture- Free Lessons Lost Ineffective Critical Control Verification Processes Field Leadership Efforts Misdirected Disconnect between Board Room and Shop Floor Barry Formosa, Vice President HSEC, Energy Coal, March Slide 3

4 Learning's from Fatality Review Low Injury Rates do not mean Low Fatality Rates High Near Miss and High Potential ti Hazard reporting often correlates with Declining Serious Injuries and Fatalities Injury Reduction Programs alone will not Prevent Fatalities A complimentary focused effort is required on Fatal Risk and Catastrophic Risk Mature Levels of Hazard Identification and Risk Awareness across the Workforce are Fundamental for Success High Management Attention after Fatalities delivered Short Term Improvement Barry Formosa, Vice President HSEC, Energy Coal, March Slide 4

5 The Safety Cycle High Management Attention cidents erious inc Se Low Management Attention Time Page 5

6 Back to Basics - No Silver Bullets 1. Leadership Create the Enabling Environment (People) 2. Specific Plan and Focus on Fatal and Catastrophic Risk 3. Measure and Reward the Right Things 4. Recognise Fallibility and Complacency 5. Stick to the Knitting - don't Chop and Change Barry Formosa, Vice President HSEC, Energy Coal, March Slide 6

7 1. Leadership Create the Enabling Environment Right People Right Structure Right Plant and Equipment Right Procedures, Standards and Safe Systems of Work Establish Accountability - Line vs. Function Set Clear Expectations for each Level of Work Provide Sufficient Time, Support and Leadership Its all about People: Value and Engage them Barry Formosa, Vice President HSEC, Energy Coal, March Slide 7

8 HSEC Plan on a Page Guiding Principles Enabling Environment Set by Leadership Key Focus Areas Objective Health BHPB Charter values BHPB GLDs BHPB Operating Model EC Letter of Intent Right people Right tools and equipment Right procedures and systems Sufficient time, support and leadership Right choices by individuals and teams Reduce Occupational Exposures Manage Fatigue Safety Eliminate Multiple Fatalities Eliminate Single Fatalities Field Leadership Environment Effectively manage water Rehabilitate disturbed areas Improve energy efficiency and reduce emissions i Community Establish effective relationships with stakeholders & deliver valued community investment programs Z E R O H A R M & S U S T A I N A B I L I T Y Barry Formosa, Vice President HSEC, Energy Coal, March Slide 8

9 Leadership Expectations General Manager General Manager is to: Spend 1 2 hours/day in field observing, coaching and std setting. Set clear expectations with reports on time and interactions in field Establish: Effective span of control and clear line accountability for performance Visible field leadership program and schedule for: Planned task observations Critical task observations Behavioural based observations Coaching and standard setting Active recognition programs Monitor progress against the plan Ensure people are given the time, tools, systems of work and support to be successful Barry Formosa, Vice President HSEC, Energy Coal, March Slide 9

10 2. Specific Focus on Catastrophic and Fatal Risk Identify and Manage Catastrophic Risk Identify and manage Fatal Risk Energy and Effort into Prevention not Reaction Critical Control Effectiveness Operating Discipline Effective Visible Field Leadership Program Planned and Scheduled Verification Activities Barry Formosa, Vice President HSEC, Energy Coal, March Slide 10

11 Specific and Deliberate Focus on Fatal and Catastrophic Risk Personal Injury Fatal Risk Catastrophic Risk Barry Formosa, Vice President HSEC, Energy Coal, March Slide 11

12 Catastrophic Risk Management RISK OWNER: BOW-TIE DIAGRAM DATE: Identify Catastrophic Risks Develop Bow Ties Identify Critical Controls RISK ISSUE: (RISK SOURCE) CAUSES IMPACTS 1 1 EVENT EXISTING PREVENTATIVE EXISTING MITIGATING 5 5 CONTROLS CONTROLS LIKELIHOOD MFL 9 9 SEVERITY FATALITIES RRR US$M LINK TO LINK TO EXISTING MITIGATING CONTROLS EXISTING PREVENTATIVE CONTROLS CONTROL OWNER CONTROL OWNER CAUSES IMPACTS IMPROVEMENT TASKS TASK OWNER DUE DATE IMPROVEMENT TASKS DUE DATE TASK OWNER Develop Performance Standards for Critical Controls Implement Critical Control Verification Process Link Critical Task Observations to Critical Controls Barry Formosa, Vice President HSEC, Energy Coal, March Slide 12

13 Fatal Risk Management Identify Fatal Risks Develop and Implement Control Standards Implement Control Standard d Verification Activities iti Link Field Leadership Activities to Fatal Risks Controls Link Hazard and Near Miss Reporting to Fatal Risks Measure Quality of Verification Processes Barry Formosa, Vice President HSEC, Energy Coal, March Slide 13

14 Hierarchy of Verification Activities High Management Involvement Safety Management Systems Audits System Focused Themed Audits All activities may have a cross section of involvement Workplace Condition Audits Critical Task Observations Field Leadership Planned Task Observations High Workforce Involvement Safety Contacts / Safety Observations On the job Risk Assessments such as JHAs, Take 5 s 5s etc People Focused Barry Formosa, Vice President HSEC, Energy Coal, March Slide 14

15 3. Measure the Right Things Shift Focus from Outcome to Potential Filter trends and events based on Potential Measure Effectiveness of Field Leadership Activities Capture and Drive down High Potential Events (Energy Release) Reward and Encourage Free Lesson Reporting (Zero Energy Release) Link Recognition and Reward to Measures Barry Formosa, Vice President HSEC, Energy Coal, March Slide 15

16 4. Recognise Fallibility Maintain Constant Sense of Vulnerability Low Injuries brings Complacency and Blind Spots Know your Red Flags e.g: Simultaneous Operations High Stored or Potential Energy Work Unplanned / Unscheduled Activities Changed Circumstances Critical Tasks with Soft Controls (Operating Discipline) Low Reporting of Hazards and Deteriorating Trends Barry Formosa, Vice President HSEC, Energy Coal, March Slide 16

17 5. Stick to the Plan Year after year after year Certainty brings stability, alignment, focus & understanding Monitor Buy in and Engagement g at all Levels Cultural Change not Climate Change (Sustainable) Barry Formosa, Vice President HSEC, Energy Coal, March Slide 17

18 Learning's from Fatality Review Low Injury Rates do not mean Low Fatality Rates High Near Miss and High Potential ti Hazard reporting often correlates with Declining Serious Injuries and Fatalities Injury Reduction Programs alone will not Prevent Fatalities A complimentary focused effort is required on Fatal Risk and Catastrophic Risk Mature Levels of Hazard Identification and Risk Awareness across the Workforce are Fundamental for Success High Management Attention after Fatalities delivered Short Term Improvement Barry Formosa, Vice President HSEC, Energy Coal, March Slide 18

19 Strategic Approach High levels of Reporting are a Positive and Healthy Lead Indicator supporting: Mature safety awareness and hazard identification in the workforce Reliable factual data to assist with the real prevention of fatalities Openness, trust and transparency of workforce and management Increased Safety Maturity Free lessons that Identify shortcomings in the application of our systems, behaviours and procedures Barry Formosa, Vice President HSEC, Energy Coal, March Slide 19

20 Additional Benefits Increased Awareness, Energy and Focus around key Fatal Risks Impetus for other sites to review their operation for similar il risks Real and Valuable information for use in tool-box talks, safety communications, Training i Programs and Risk assessments Provides a Focus for Field Leadership Activities iti such as Planned Task and Critical Task Observations Barry Formosa, Vice President HSEC, Energy Coal, March Slide 20

21 Zero Energy / Zero Barrier Model Zero Barrier i.e. Lucky no fatality or significant outcome Serious breakdown in preventative systems Zero Energy / High Potential Hazard i.e. no energy released no harm Near Miss i.e. energy released but no harm Zero Barrier Incident Latent Barriers No risk assessment or PTW completed for working at height activity Time Guard Rail Person Person Person not in observed standing place working at on hand around height with rail, open void no fallrestraint wearing fall- restraint falls 4 metres Immediate standing on hand rail, not wearing fallrestraint falls 4 metres Barry Formosa, Vice President HSEC, Energy Coal, March Slide 21

22 Zero Energy Significant Incident Reporting Energy Release Events Drive occu urrence dow wn Zero Barrier Significant Incident with Impact Near Miss No Energy Release Reporting up Drive Zero Energy Incident Barry Formosa, Vice President HSEC, Energy Coal, March Slide 22

23 Encouraging Results and Trends Barry Formosa, Vice President HSEC, Energy Coal, March Slide 23

24 Some recent key learnings Barry Formosa, Vice President HSEC, Energy Coal, March Slide 24

25 Recent Key Learning's Have not yet fully influenced and valued the Operators, Front line and Second Line who ultimately control how the work is done Quality and Effectiveness of Field Leadership and Verification Processes Wanting Barry Formosa, Vice President HSEC, Energy Coal, March Slide 25

26 Thankyou! Barry Formosa, Vice President HSEC, Energy Coal, March Slide 26