ASMC Safety Conference

Transcription

1 ASMC Safety Conference Achieving the best outcome as different safety cultures collide March 2013

2 Todays Agenda Overview Organisational History Sucrogen Safety Management System 2012 Sucrogen Safety Statistics / Incidents Sucrogen Safety Challenges The Plan Ahead Discussion / Questions. 2

3 Overview Todays discussion is about Sucrogen and the Proserpine Mill and the challenges that are faced to integrate two different systems / cultures. Sucrogen 2010 CSR Sugar starts to split off its sugar division to Sucrogen Multi division business Systems in a state of change Proserpine Mill December 2011 Proserpine Sugar Mill purchased by Sucrogen single entity Good documentation, Implementation had fallen away. 3

4 History - Sucrogen Previously CSR Sugar Division Purchased by the Wilmar Group in 2010 Wilmar Singapore based company Palm Oil based industries Sucrogen business divisions Cane Products Sweetners Bio-ethanol Cane Products 8 sugar mills - Proserpine Sugar Mill (purchased December 2011) Sugar cane production (approx 450K 2013) Harvester Contract (approx 450K 2013) Generate ~ 200 MW of electricity with ~120 MW to grid as export Approximately 2100 staff and employees All systems under Review / Development after Sucrogen purchase. Previous systems were regionally based and not consistent across the group 4

5 History - Proserpine Sugar Mill Established in early 1900 s Previously owned by Proserpine Sugar Mill Ltd a co operative owned factory Single entity organisation Documents / procedures only require site approval Purchased by Sucrogen December 2011 Site culture strained by a number of years of uncertainty Furfural Plant The factory has areas of high quality documentation Implementation of procedures etc had slipped over the past years Safety plan provided to Division of WH&S September 2012 Basis of plan was to integrate the Proserpine safety system into the Sucrogen Framework. 5

6 Sucrogen Safety Management System Previous Safety Management System - CSR SHEMS Took into consideration Timber, Building Products, Quarries and Sugar. The Sucrogen SHE Framework was issued in March 2011 Establishes high level expectations ( design criteria ) for safety requirements across Sucrogen. Sucrogen Self Insurer Required to maintain a Safety Management System Need to meet the requirements of the National Audit Tool (NAT) NAT aligned with Australian and New Standard AS/NZS4801 (Occupational Health and Safety Management) 6

7 Sucrogen Safety Management System Sucrogen Brand Personality Framework Framework Framework Policy Policy Policy Policy Policy Policy Policy Policy Policy Standard Standard Standard Business Corporate Corporate Corporate Unit Business Procedure Corporate Procedure Corporate Procedure Corporate Unit Business Procedure Corporate Procedure Corporate Procedure Procedure Corporate Procedure Unit Procedure Procedure Procedure Procedure Work instruction Work instruction Work instruction 7

8 Sep-07 Dec-07 Mar-08 Jun-08 Sep-08 Dec-08 Mar-09 Jun-09 Sep-09 Dec-09 Mar-10 Jun-10 Sep-10 Dec-10 Mar-11 Jun-11 Sep-11 Dec-11 Mar-12 Jun-12 Sep-12 Dec-12 Sep-07 Dec-07 Mar-08 Jun-08 Sep-08 Dec-08 Mar-09 Jun-09 Sep-09 Dec-09 Mar-10 Jun-10 Sep-10 Dec-10 Mar-11 Jun-11 Sep-11 Dec-11 Mar-12 Jun-12 Sep-12 Dec-12 Achieving the best outcome as different safety cultures collide Sucrogen Safety Statistics Safety Reporting Pyramid (Month Numbers) LTI - 18 Recordable Injury TRIFR 16.9 First Aid Injury 451 Near Hit Safety Walks LTIFR

9 Proserpine Sugar Mill TRIFR and LTIFR 9

10 2011 / 2012 Comparison. Cane Products Safety Statistics Comparison 2011 / 2012 excluding Proserpine Mill TRIFR LTIFR SR Total # Total # Total # Total # Total # MAT MAT MAT Days LTI RW MT Incidents % Reduction

11 Incidents in review. November 2012 Proserpine Mill Fatality Employee struck by empty Cane Bin August 2012 Inkerman Mill Finger amputation Employee s hand made contact with Cutter Grinder Mobile Equipment near misses and incidents 3 rd party interaction with locomotives Cane harvesting near misses Plane Boiler Incident Process safety issues identified. 11

12 The Challenges Ahead Consistently implement the Safety Management System (SMS) across the group i.e. Mills, CS&T, Farms and now to include Ethanol Understand why can some sites reach Zero LTIFR and TRIFR and other sites struggle to manage incidents / injuries Why do some sites score lower in the SMS Audit but have favorable Lag indicators and vice versa Integration of Proserpine system into Sucrogen Framework Documentation - Implement the critical Risk Management Process Practical application e.g. PTW & Isolation process part of the critical 5 Culture - Rush to crush no longer accepted Behaviors The journey to interdependence Compliance to Commitment Safety Injuries / Incidents Sucrogen lag indicators have flat lined How to decrease the number injuries / incidents 12

13 The Plan Ahead Safety Plan established for both the Business Unit and the individual sites. Focused completion of a defined number of procedures i.e. complete a small number rather than work on a large number of documents but not complete any Permit to Work Confined Space Working at Heights Isolation Hot Work Focused completion on a defined number of projects Reporting system / Corrective Actions Register Contractor Management Risk Management Define the next stage of the BBS program Safety Walks to be the corner stone of the program (engagement and observation) Audit program to continue External and Internal programs 13

14 Questions? 14