Hinze-Zero Accidents Best Practices (4MB)

Zero AccidentsBest PracticesPresented by Jimmie HinzeUniversity of Floridahinze@ufl.edu

ZEROIncidentsSession 1Introduction: Injury Statistics

Construction Fatalities by YearConstruction Worker Fatalities2007-2009

How Do We GenerallyMeasure Safety?• Most common: Injury Frequency >• OSHA recordable injuries per 200,000hours, also called the recordableincidence rate (RIR)

What are OSHArecordable injuries• Injuries that require treatment by a physician• Worker becomes unconscious at work• All lost time injuries and fatalities are recordable >• If a physician conducts a diagnostic test on aninjured worker but does not perform treatment, it isnot a recordable injury

Computing the RIR• Assume a project worked 400,000hours and incurred 8 recordableinjuries.• What is the RIR?8400,000x 200,000 = 4.0

A Disproportionate Number ofU.S. Accidents Occur inConstruction• 6 to 7% of the industrial workforce is inconstruction.• Nearly 20% of the fatalities occur inconstruction.• Over 12% of the disabling injuries occur inconstruction.• Do these statistics have anything to do withfirms serious about safety?Source: U.S. Department of Labor Statistics

Costs of Injuries and SafetyHighCost of InjuriesCostLowInvestment in SafetyLowLevel of Effort andEmphasis on SafetyHighConceptual Representation

EMR Modifies the Workers’Compensation Premium• Example:• Cost of Workers’ Compensation based on themanual rate for the example company was$1,000,000.• Assume the EMR is 0.8.• Workers’ Compensation premium actually paid is$1,000,000 X 0.8 = $800,000.• If the EMR is 1.1, the premium = $1,100,000.

What is the average EMR?• 1.0???• That’s s a myth

Study of Contractors withVolumes of Work Over $1 MillionWorkers’ Compensation Experience Modification RatePercent of Contractors in Study454035302520151050

Session 2Causes of Accidents

Breakdown of “Other” Causes ofFatalities

How to Achieve Safety1. Provide a safe work environment.2. Don’t t permit unsafe, at-risk behavior.3. Provide a rewarding work environment.4. Make everyone responsible for safety.

ZEROIncidentsSession 3Good Safety Practices:Demonstrated ManagementCommitment, Staffing for Safety, andSafety Planning

Zero AccidentsTwo StudiesInformation obtained from largeconstruction firms through SurveysSite interviews on large constructionprojectsSource: CII Research Summary 160-1,1,Safety Plus: Making Zero Accidents A Reality

Zero Accidents Study• Varied Industries• Petrochemical• Industrial• Public works• Transportation• Hotel-casino• Commercial buildings• U.S.-wide geographic area• $50–$600 $600 millionSource: CII Research Summary 160-1,1,Safety Plus: Making Zero Accidents A Reality

DemonstratedManagement Commitment• Includes headquarters and siteleadership.

Demonstrated Management CommitmentWhat portion of the recordable accidents areinvestigated by top management?Recordable Incident Rate6543210Every InjuryHalf or less

Demonstrated Management Commitment• Does the company president or seniormanagement review safety performance reports?Recordable Incident Rate7.006.005.004.003.002.001.000.00YesNo

Demonstrated Management Commitment• How frequently does the home officeperform safety inspections on the project?3.00Recordable Incident Rate2.502.001.501.000.500.00Weekly orBi-weeklyMonthly orAnnually

Safety Staffing• Safety is everyone’s s responsibility.• Trained safety personnel are keyresources.

Safety Staffing• How many workers per safety person?2.50Recordable Incident Rate2.001.501.000.500.00Up to 50 Over 50

Safety Staffing• To whom does the safety representative report?2.50Recordable Incident Rate2.001.501.000.500.00Corporate orStaffLine orProject

Safety Planning• Safety Risk Analysis of the Project• Development of the Site-specificSafety Plan• Job Hazard Analysis of IdentifiedSafety Risk Areas• Pre-Task Planning

Safety Planning• Does the project have a site-specific specific safety program?6.00Recordable Incident Rate5.004.003.002.001.000.00YesNo

Safety Planning• Are pre-task meetings held?3.00Recordable Incident Rate2.502.001.501.000.500.00YesNo

ZEROIncidentsSession 4Good Safety Practices:Safety Training and Education,Worker Involvement, andParticipation, Recognition, and Rewards

TrainingTransferring information to the workers

Safety Training and Education• Is safety training a line item within the budget?3.00Recordable Incident Rate2.502.001.501.000.500.00YesNo

Safety Training and Education• Does every worker on site receive a safety orientation?6.00Recordable Incident Rate5.004.003.002.001.000.00YesNo

Safety Training and Education• Type of safety orientation provided to workersRecordable Incident Rate4.003.503.002.502.001.501.000.500.00FormalInformal

Safety Training and Education• How much monthly training do workersreceive after orientation?3.00Recordable Incident Rate2.502.001.501.000.500.00OverFour HoursUp toFour Hours

Safety Training and Education• When are toolbox safety meetings held?3.50Recordable Incident Rate3.002.502.001.501.000.500.00DailyTuesday–ThursdayMonday

Testing after Training Sessions• Are attendees at training sessions given atest at the conclusion of the training period?3.00Recordable Incident Rate2.502.001.501.000.500.00YesNo

Worker Involvement

Worker Involvement and Participation• Does a formal worker behavior observationprogram exist on the project?3.00Recordable Incident Rate2.502.001.501.000.500.00YesNo

Worker Involvement and Participation• Total number of safety observationreports filed per 100,000 worker hoursMedian Recordable Incident Rate21.510.50More Than 100 Up to 100

Worker Involvement and Participation• Are safety perception surveysconducted on the project?3.00Recordable Incident Rate2.502.001.501.000.500.00YesNo

Other Means of WorkerInvolvement• Safety Committees• Toolbox Meetings• Job Hazard Analysis• Incident Investigations• Others?

Recognition and Rewards• Does the project have a formal workerincentive program?Recordable Incident Rate3.503.002.502.001.501.000.500.00YesNo

Recognition and Rewards• How often are incentives given to workers?Recordable Incident Rate3.503.002.502.001.501.000.500.00Weekly or Bi-weeklyQuarterly

Recognition and Rewards• Do family members attend safety dinners?2.50Recordable Incident Rate2.001.501.000.500.00YesNo

Recognition and Rewards• Are field supervisors evaluated on safety?9.00Recordable Incident Rate8.007.006.005.004.003.002.001.000.00YesNo

Session 5Good Safety Practices:ZEROIncidentsSubcontractor Safety Management,Accident/Incident Investigations, andDrug Testing

SubcontractorManagement

General Contractor Influence on SubcontractorSafety Performance on Small Projects• Relative Importance to SafetySource: CII Publication 13-1,1, Managing Subcontractor Safety

General Contractor Influence on SubcontractorSafety Performance on Large ProjectsEmphasize Safetyin CommunicationsProvide EfficientCoordination

Subcontractor Management• Are subcontractors required to submit site-specific safety plans?Recordable Incident Rate4.003.503.002.502.001.501.000.500.00YesNo

Subcontractor Management• Do all subcontract workers attend a formalsafety orientation?6.00Recordable Incident Rate5.004.003.002.001.000.00YesNo

Subcontractor Management• How frequently do subcontractors hold safety meetings?2.50Recordable Incident Rate2.001.501.000.500.00DailyWeekly

Subcontractor Management• Are there sanctions for subcontractornon-compliance with safety standards?6.00Recordable Incident Rate5.004.003.002.001.000.00YesNo

Accident/IncidentReporting andInvestigation

Accident/Incident Reporting and InvestigationNumber of near-misses recorded per 100,000 hours2.5Recordable Injury Rate21.510.505 or more less than 5

Accident/Incident Reporting and InvestigationWhat portion of the recordable accidents areinvestigated by top management?Recordable Incident Rate6543210Every InjuryHalf or less

Drug Testing

3.00Drug TestingAre random drug tests conducted?Recordable Incident Rate2.502.001.501.000.500.00Yes(22)No(14)

Drug TestingWhat percentage of random tests are positive?Recordable Incident Rate2.521.510.50Less than 10%10% or More

Drug TestingWhat percentage of the workforce was testedin random tests?Recordable Incident Rate1.41.21.00.80.60.40.20.0100% Testing(4 firms)Typically 10% Testing(23 firms)

Drug Testing:Is follow-up testing conducted?Recordable Incident Rate1.41.21.00.80.60.40.20.0Yes(5)No(22)

Drug TestingDoes the owner require the contractor to dodrug testing?Recordable Incident Rate4.003.503.002.502.001.501.000.500.00Yes(53)No(4)

Key Practices in Getting toZero• Demonstrated management commitment• Staffing for safety• Safety planning – pre-project project / pre-task• Safety training and education• Worker involvement and participation• Recognition and rewards• Subcontractor management• Accident/incident reporting and investigation• Drug and alcohol testing

Project Safety PerformanceResults of implementing key practicesRecordable Incident Rate4.003.002.001.003.843838workersworkersperper100010002.002020workersworkersperper1000100022workersworkersperper100010000.170.00Jobs ThatImplementno morethan 40%SampleMeanImplement46 to 84%Jobs ThatImplement 85%or moreSource: CII Research Summary 160-1,1, Safety Plus: Making Zero Accidents A Reality

ZEROIncidentsSession 6People Resourcing, Planning,and Scheduling for Shutdowns,Turnarounds and Outages

Unique Nature ofShutdowns andTurnarounds• Rapid Buildup of the Workforce• Tight Schedule (“Round(Round-the-Clock Effort”)

Key Practice ResultsIdentified best practices result insignificantly lower recordable injury rates.These represented the best of the best.

Rapid Buildup of the WorkforceWhere do the shutdown workers come from?2.50Recordable Incident Rate2.001.501.000.500.00From the area, butnot familiar withprojectTransfer from otherprojects, familiar withtype of work done

Planning and SchedulingIs software used to schedule the project?Recordable Incident Rate3.503.002.502.001.501.000.500.00YesNo

Planning and SchedulingWhat units of time are used on the project schedule?1.6Recordable Incident Rate1.41.21.00.80.60.40.20.0DaysShiftsHours

Worker Familiarity andScheduling by the Hour2.0Recordable Incident Rate1.51.00.50.0Not Familiarand NotSchedule byHoursFamiliar orSchedule byHoursFamiliar andSchedule byHours

Worker FatigueDuration of Shutdowns1.210.80.60.40.20Less than 2 WeeksTwo Weeks or Longer

Project Safety Performance onShutdownsResults of implementing key practicesRecordable Incident Rate2.502.001.501.000.500.002.37ImplementLess Than40%2424workersworkersperper100010000.79ImplementAt Least80%88workersworkersperper1000100000workersworkersperper100010000.00ImplementAll

ZEROIncidentsSession 7Owner’s s Role in Safety

Conducting the Research• Personal interviews• Owner Project Management• Contractor Project ManagementSource: CII Research Summary 190-1,1,The Owners’ Role in Construction Safety

Types of ProjectsPublic10.2%New50%Renovation 19%Shutdown 10%Private89.8%Combined 10%Maintenance 5%Manufacturing 32.2%Commercial 6.8%Civil work 1.7%Utilities 8.5%Petrochemical 50.8%Open Shop32.2%Union32.2%Mixed35.6%

Project CharacteristicsWhat type of owner?RIR3.503.002.502.001.501.000.500.00PrivatePublic

Project CharacteristicsWhat type of contract?2.502.00RIR1.501.000.500.00Design-BuildGeneral Contract

Project CharacteristicsShutdowns versus other types of projects3.002.50RIR2.001.501.000.500.00ShutdownsAll Others

Project CharacteristicsHow many shifts?3.002.50RIR2.001.501.000.500.00OneTwo or Three

Project CharacteristicsHow many days worked per week?3.002.50RIR2.001.501.000.500.00Four or FiveSix or Seven

Selection of SafeContractors

Selection of Safe ContractorsHow important is safety in contractor review?(7 is most important)3.002.50RIR2.001.501.000.500.005 or less 6 or 7

Selection of Safe ContractorsIs RIR used to evaluate contractor safetyperformance?3.002.50RIR2.001.501.000.500.00YesNo

Selection of Safe ContractorsWhat is the highest acceptable RIR for contractorselection?3.002.50RIR2.001.501.000.500.00Less than2.02.0 orGreaterNoneSet

Selection of Safe ContractorsAre personnel qualifications reviewed whencontractor’s s safety is evaluated?RIR3.503.002.502.001.501.000.500.00Safety StaffProject Mgmt. TeamYesNo

Contractual SafetyRequirements

Contractual Safety RequirementsDoes the contract require at least one full-timesafety professional on site?RIR3.503.002.502.001.501.000.500.00YesNo

Contractual Safety RequirementsDoes the owner approve contractor safetyprofessionals?RIR3.503.002.502.001.501.000.500.00YesNo

Contractual SafetyContractor Must:Requirements• Provide specified minimum training for workers.• Submit a site-specific specific safety plan.• Submit a safety policy signed by contractorCEO.

Owner’s s Involvementin Safety ManagementDuring ProjectExecution

Owner’s s Involvement in SafetyManagement During ProjectExecutionSafety Program Components• Emergency plan (medical and hazardous materials)• Daily JSA (Job Safety Analysis) conducted on project site• Substance abuse program• Specific safety training program• Task-specific specific personal protective equipment (PPE) analysis• Safety responsibility defined for all levels• Emergency response team maintained on the project

Owner’s s Involvement in SafetyManagement During ProjectExecutionSafety Program Components (continued)• Prime contractor’s s employees to have 10-hour OSHA cards• OSHA specific regulations• Prime contractor’s s supervisors to have CPR and first aid cards• Training on the hazards related to job tasks• Pre-project safety planning• Conduct regular safety inspections• Incident reporting and investigation• Regular safety meetings

Owner’s s Involvement in Safety ManagementDuring Project ExecutionDoes the owner maintain injury statisticsby contractor?3.002.50RIR2.001.501.000.500.00YesNo

Owner’s s Involvement in Safety ManagementDuring Project ExecutionAre contractor injury statistics included in theowner’s s safety performance?3.002.50RIR2.001.501.000.500.00YesNo

Owner’s s Involvement in Safety ManagementDuring Project ExecutionDoes the owner provide extra funds (outsidethe contract) to promote project safety?3.002.50RIR2.001.501.000.500.00YesNo

Owner’s s Involvement in SafetyManagement During Project ExecutionDoes the owner participates in the safetyrecognition program?RIR3.503.002.502.001.501.000.500.00YesNo

Owner’s s Involvement in Safety ManagementDuring Project ExecutionWho participates in worker orientation?3.503.002.50RIR2.001.501.000.500.00ContractorOwnerOwner andContractor

Owner’s s Involvement in SafetyManagement During Project ExecutionDo owner’s s representatives participate in safetyand/or toolbox meetings?RIR3.503.002.502.001.501.000.500.00YesNo

Owner’s s Involvement in Safety ManagementDuring Project ExecutionDoes the owner’s s safety representative check projectsafety inspection records?RIR3.503.002.502.001.501.000.500.00YesNo

Owner’s s Involvement in SafetyManagement During Project ExecutionAre near-misses and job safety inspection reportsmonitored?RIR7.006.005.004.003.002.001.000.00BothNeither

Owner’s s Involvement in SafetyManagement During Project ExecutionWhat is the owner’s s established goal for project RIR?3.002.60RIR2.502.001.501.381.951.000.500.00ZeroGreaterthan zeroNoobjective

ZEROIncidentsSession 8IMPLEMENTING FOCUSEDSAFETY INITIATIVESDeveloping a program toaddress specific hazards

Safety Performance – ContinuedImprovement4.3

What Contributed to the Improvement inSafety Performance?1. Worker Orientation2. Toolbox Safety Meetings3. Job Safety Analysis4. Jobsite Safety Inspections5. Safety Recognition Awards6. Drug Testing7. Pre-Task Planning8. Safety Committees9. Incident Investigations10.OthersOthers1.2.3.4.5.6.7.8.9.10.

What is a FocusedSafety Initiative?A Program that is Designed toAddress a Specific Hazard

Research ObjectiveIdentify a Pattern in the Development andImplementation of Programs that areDesigned to Address Specific HazardsDevelop a Model or Template

Examples of CaseStudies•Hand Hazards•Underground Metal Detection•Barricade Tape Program•Loading and Unloading Trailers•Eye Hazards•Fall Protection for Steel Erection•Housekeeping•Back Strains

Program to Address HandHazardsFacility Construction &Services' Injuries by Body Part25Focused Program InitiatedNumber of Injuries201510HandInjuriesHands/FingersWristFace/Teeth/Mouth/EyesArm/ShoulderChestLeg, footBackNeckMultiple body parts50Year2000 2001 2002 2003 2004 2005 end of June

Program Focusedon Eye HazardsEye injuries constituted 41% ofall worker injuries on a powerplant project.

Eye Injuries were Running Out ofControl

High Number of EyeInjuries Despite a 100%Eyewear Policy•Conditions were severe (esp.iron filings)•Non-compliance had crept in

Focus was to TurnThings Around•Workers were reminded about eye safety•Letters were sent to the workers stressingeye safety•Meetings stressed eye safety•Eye safety posters were posted

DAUGHTER’SWEDDING2005

Implementation Case StudyYielded Dramatic Improvements

Safe Loading and Unloading of Trailers

Safe Zone3 Stanchions (min)4 ft 4 ftLadders Tied OffNo Double‐Tier Stacking of MaterialsTaglines attached to RiggingCrane Operators Trained on the new Procedures

Results: No injuries in 1,000 Loadsand 500,000 hours of workHigh Level of Compliance

Focused Safety Implementation ModelInitiationBenchmarkChampionDevelopmentImplementationMonitoringCorrective ActionMeasure of SuccessSuccess Recognition

Focused Safety Implementation ModelInitiationBenchmarkChampionDevelopmentImplementationMonitoringCorrective ActionMeasure of SuccessSuccess RecognitionEstablishedPolicy

ZEROIncidentsSession 9The Value of LeadingIndicators

Measuring SafetyPerformanceNumber of OSHA CitationsClaims HistoryEMRLost Workday Case RateOSHA Recordable Injury Rate

MeasurementManager action often uses the “failurebased” measurement tools(management by exception)But these should be balanced withthose that promote best practices(management by objective).

•Traditional view of safety is from thepessimistic perspective.( The focus is on our failures ormanagement by exception) >•Can we or should we change the waywe look at safety?

Measurement is important toevaluate the efficiency of a processInputProcessoutputActions thatPromote SafeWork PerformanceOccurrenceof Injuries

Focus of SafetyManagement• Behavior – this can be changed and itcan be controlled• Focus on behavior that will lead tosuccess (management by objective)

Two Types of Indicators• Lagging• Downstream• TrailingLeadingUpstreamPredictive• Reactive ResponseResponseProactive

Trailing or Lagging Indicators ofSafety PerformanceLaggingIndicatorsFatalityLost Time InjuryMedical Case InjuryFirst aid injury60000Near Miss incidentsLeadingIndicatorsUnsafe Conditions andUnsafe BehaviorEfforts toReduceIncidentOccurrencesUnderlying Causes for UnsafeBehavior and Unsafe Conditions

Advantage of Using LaggingIndicators of Safety (the RIR andthe EMR)Advantages:They are accurate (hindsight is 20-• They are accurate (hindsight is 2020)• RIR and EMR are available for mostfirms• They are widely accepted measures• We think we understand thesemeasures..

Disadvantages:• They are purely historical in nature• No information is generally availableon what specific actions might betaken to improve the situation• Data can be manipulated

Why has the industry adoptedthe lagging indicators?• These are used to satisfy regulatoryrequirements• Insurance companies use them >• But are our safety needs the same asthe regulatory and insurance bodies,if we truly want to aggressivelypromote safety?

The Construction ProcessContractor Project SuperintendentsSubcontractorsDesigners Workers Foremen Owners Managers PoliciesSafety Performance ??

Should we change to a greateruse of leading indicators?• This is not a suggestion that laggingindicators will disappear• Leading indicators provide a newapproach to safety because theyhave a different purpose..

Leading Indicators of SafetyPerformance• They are focused on the safetymanagement process (not justnumbers)• They provide an indication(prediction) of the safetyperformance to be realized on aproject..

What is the best leadingindicator of safety? >• There probably is no best leadingindicator• The indicators cover differentprocesses so different indicators willbe needed

Advantage of Using LeadingIndicators of Safety Performance• If performance indicators are poor orunacceptable, modifications orchanges can be made before injuriesactually occur• Focus is on the process, not the endresult

A Case Study• Large Projects (over 400,000 hours)• Very Aggressive in Safety Promotion• RIR of 0.56• Monitored 10 Leading Indicators ofSafety

• Percent of worker observations thatwere safe (A)• Number of positive reinforcementsprovided per 200,000 hours (B)• Percent closed audit findings (C)• Percent of orientation sessions withOwner participation (D)

• A=1 if the percentage is less than 90, 2 ifthe percentage is 90-95, 95, 3 if 95 or greater• B=1 if the number is less than 250, 2 ifbetween 250-1000, 3 if 1000 or greater• C=1 if the percentage is less than 70, 2 ifthe percentage is 70-95, 3 if 95 or greater• D=1 if the percentage is less than 70, 2 ifthe percentage is 70-90, 3 if 90 or greater

Score = 3A + 3B + C + DRIR=

Worker Observations and PositiveReinforcement: Score = A + BRIR1.61.41.210.80.60.40.20avg=1.13avg=0.34avg=0.11Score = 3 Score = 4 Score = 5 or 6

Let’s s Start Using LeadingIndicators of Safety• Let’s s not measure our injuries,let’s s prevent them.• Focus on strengthening areas ofweakness in the safety processthat contribute to injurycausation..

Conducting A SelfAssessmentWhat Are the Weaknesses inYour Firm? >Develop a Strategy andAddress the Weaknesses

Owner ScorecardProject Context, Contractor Selection, Contractual Safety Requirements and Owner Involvement inProject SafetyProject context:(1) Does the project work one shift?(2) Does the project work five days a week or less?Selection of contractor(3) Is the TRIR requirement for the contractor selection less than 2.0?(4) Are the qualifications of the project team reviewed?(5) Are the qualifications of the safety staff reviewed?(6) Does the evaluation of each contractor’s safety performance make a difference in awarding the contract?

Owners Scorecard (continued)Contractual safety requirements(7) Does the project use a design-build contract?(8) Does the contract require the contractor to place at least one full-time safety representative on the project site?(9) Does the contract require the contractor to submit all safety personnel résumés for the owner’s approval?(10) Does the contract require the contractor to prepare a site-specific safety plan?(11) Does the contract require the contractor to submit a safety policy signed by its CEO(12) Does the contract require the contractor to provide a minimum specified amount of training to the construction workers?

Owners Scorecard (continued)Contractor Safety Program RequirementsWhich of the following are required to be included in the contractor’s safety program?(13) Contractor must prepare a plan for site emergencies(14) Contractor must conduct pre-task safety planning on the project site(15) Contractor must implement a substance abuse testing programOwner’s involvement in project safety management(16) Does the owner's safety representative investigate near misses?(17) Are injury statistics on the projects maintained separately on each contractor?(18) Are all project injuries included in the owner’s overall measure of safety performance?(19) The owner actively participates (gives presentations) during worker safety orientation?(20) Comprehension of safety training is evaluated through testing?Which of the following activities are performed by the owner’s site safety representative?(21) Enforcing safety rules and regulations(22) Monitoring of the implementation of pre-task planning(23) Participating in safety recognition programs(24) Participating in safety and/or tool box meetings(25) Does the owner set zero injuries as its safety expectation before the commencement of site work?

Scorecard Values and Safety Performance54.543.532.521.51Recordable Incident RateRecordable Incident Rate0.50Score = 88%

ZEROIncidentsIt’s s All About PeopleMaintaining the sustainabilityof our construction workers isour highest goal

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