HSE Excellence Journey - sqfiei.insqfiei.in/convention2017/presentations/DAY 1/technical session...
Transcript of HSE Excellence Journey - sqfiei.insqfiei.in/convention2017/presentations/DAY 1/technical session...
HSE Policy & Systems
Essar Steel strongly believes in the saying
“Nothing is more important than the Safety & Health of people who work in the plant”
The foundation of our Strong HSE Management System are
•HSE Policy
•Safety Mandates – A Fatality Prevention Tool
•HSE Cardinal Rules
•HSE Code of Conduct
Directly emphasizing that HSE is at the center of our business planning,
designing and decision making process
Now let us witness our HSE Initiatives taken towards our Journey of HSE
Excellence over the past Five years and how we laid the foundation for
“Building a Sustainable Safe Culture at Essar Steel.”
HSE Management Systems
O HSAS - 18001 :2007 , I SO -
14001 :2004 – I NT EG RAT ED
MAN AG EMENT SYST EM ( I MS)
BRI T I SH SAF ET Y CO UNCI L F I VE
STAR RAT I NG SYST EM, UK
PRO CESS SAF ET Y MAN AG EMENT
SYST EM (PSM) I N L I NE W I T H
O SHA STAND ARD 1910 . 119 .
Level 1 – Online HSE Training:
• Online HSE Training for all Levels of employees
Level 2 – Class Room HSE Training
• Five days HSE Induction Training for new joiners (DET’s/ GETs/ MTs)
• Two days certified training for Laterals
Level 3 – Rotational Training:
Plant HSE Managers are pulled out for a period of 6 months in HSE and put through rigorous training.
They ensure the deliverables on Safety in their respective departments
Specific Training:
Specific Training imparted on various Risk Assessment methods, Electrical Safety, Work at Height,
Material Handling, Work Permit System, LOTO, Legal requirements, Behavioral Based Safety,
Environmental Legislation etc. by internal & external experts.
Defensive Driving Training (DDT) program is made compulsory for all the drivers to undergo
this program followed by on the road assessment.
Building Safety Competencies
Contractors’ HSE Management System
• Contractor Capability Assessment Carried Out With
Respect To HSE Requirements Prior To Award of
Contract and Post Award of Contract
• Ensuring Commitment and Compliance of our
Contractors in relation to our HSE Policy.
• HSE Directive for Penalty for Safety non-compliance &
accidents for contractors
• Monitored Contractors’ HSE Performance through:
– Half-yearly Contractors HSE Performance Audit
– Conducting tripartite meeting for Contractors’
– Conducting Bi-Monthly HSE Communication meet
– HSE Induction movie introduced for Contractor
Workers
• Mandatory Competency Assessment for Safety Critical
Jobs (e.g. Crane Operators, Riggers, Working at Height
etc.)
• 1 Day Certified HSE Induction Training for Contractor Employees
• Competency Assessment & Certified Crane Operator Training
• Competency Assessment & Certified Rigger Training
• Competency Assessment & Certified Work at Height Training
16 days On the Job Safety Induction Training for contractors after Screening & Selection
9
Sr. Description Period
1 Classroom Induction training as per the departmental Module.
1 Day Do’s and Don’ts of their plant premises
Brief about Past incidents happened in the plant
2 Site visits as per the departmental module
3 Days Work at Height Training
Confined Space entry training
3 HIRAC, SOPs, SMPs, Awareness
2 Days
Emergency Preparedness for respective Plant
Safety Mandates & Work Permit System
Interaction with Area In charge/ HOD before deputation to on the job training.
HSE Directive for Penalty - Safety Non-compliance
4 On Job training in the department
a. Class Room 3 Days
b. Site Visit 7 Days
Implementation of Behaviour Based Safety Journey
• BBS Workshops to the Senior Leadership Team
• Formation of BBS Steering Committee
• Organized special Batches of BBS training to the company employees
• Identified department wise BBS Lead Trainers - 150 No's
• Launched Online Web-portal for Behavior Based Safety (BBS)
• BBS committees for developing BBS Observers
• BBS committee for Contractor developing Contractor Observers
• BBS Supporting Team for Promoting BBS through Displaying BBS Signages
/ BBS Stickers / Caps.
10
Implementation of Process Safety Management System
• PSM Workshop to the Senior Leadership Team & Company Employees
• Formation of PSM CELL- Headed by Director of Facility & VP & Head, HSE
• Apex Team – To lead the PSM elements.
• PSM Core Operating team and sub-committees in each department for Continuous
improvement.
• PSM ROADMAP
• Launched Online PSM Portal, PSM Library, Mangement of Change
• PSM Guidelines Rolled out
• PSM Elements incorporated in our Standard Operating Procedures
• Screening of PSM Video Films across the Facility
• Internal Self-Assessment & Cross Functional Audit of all PSM elements in respective
departments by Core PSM Members.
• External Audit of PSM to assess our PSM Implementation & Improvement areas
12
2010 Audit Outcome – Average score – 55% ,
2014 Audit Outcome – Average score – 92%
15
Third Party Audit by M/s Cholamandalam Ltd in the year- 2010
& M/s Prosafe Pvt Ltd in the year- 2014.
17
Safety Index - A Strategic Business Leadership Tool To
Measure The Real Time Safety Performance
Safety Index - A stringent tool for measuring and monitoring Safety Performance of
respective departments (Composite Index of Leading & Lagging Indicators) Minimum
Level for Safety Index is 95% for Individual department.
The Departments who have achieved less then 95% Safety Index are considered as
nonperformer for the particular month.
18
• The Implementation of Safety Index helped us to establish interdependent
Safety Culture and resulted drastic reduction in LTI, MTC, FAC in the year 2014,
2015 and 2016.
Graph Depicts Continual Improvement of Safety Index
World Steel Board Press Release
Safety & Health Recognition - 2014 Essar Steel - Ranked - 3rd in overall Safety Performance
Essar Steel is the 5th organisation in the World who
received 2nd time WSA Recognition in last 5 years.
20
Essar Steel has been selected for Worldsteel Safety
Excellence Recognition - 2015 in “Safety Leadership”.
World Steel Safety & Health Recognition - 2015
Set a New Safety World Record
23
Essar Steel set a New Safety World Record by achieving Lowest
LTIFR (Lost Time Injury Frequency Rate) to 0.11
LTI FR is a major Social Indicator under the sustainability
Reporting of Businesses.