Improving Employee Hazard Recognition

Cory McBride-Curt Krambeer International Paper

Cedar River MillCedar Rapids, IA

Cedar River Mill

• Largest 100% recycle-based paper mill in western hemisphere

• Two paper machines • Work force of 220 team members• We produce brown paper for boxes

SAFETY VISIONEveryone enjoying a superior quality of life

Unsurpassed personal commitment to the safety, health, and well-being of self, family,friends, and community.

Cedar River Mill

Awareness – Attitude - Action

• Do we automatically know about the “Golden Poison Frogs” in our work places?

• Everyone’s hazard recognition abilities will need a little help.

Our Message

• Communication• Communication• Communication

Further:

• Build Systems of Communications

Training

• Training for new team members– General safety training– Overview and specifics on safety processes– Overview of papermaking and related hazards

Some Topics for New Hires

• General Safety Rules• Lockout-ZES• Confined Space• Hazard Communication• Hot Work• Stop Program• Safe Start

• Chemicals• Rigging• Environmental

Concerns• Behavior-Based Safety• Papermaking Process• Housekeeping

Classroom training for new hires

• Permitted processes are covered in classroom settings

• Electrical training is included

Lockout Board for #2 Dry End

• After covering topics in the classroom, trainees are able to see processes used on the operating floor.

Training for Specific Job Skills

• Raw Materials• Shipping• Winder• Stock Prep• Wet End Paper Machine• Dry End Paper Machine• Control Room

Training

• Training for job skills– Task training including job hazards– Assisted time and unassisted time– Standard procedures that include hazard listing

Training Checklist

• Checklists for Job Skills include all SOP’s related to that particular job and contain safety items that the trainer and trainee must review and initial.

Winder Checklist

• Seven pages of items (safety aspects, standard procedures, known hazards) that must be reviewed by trainers with all trainees.

Standard Operating Procedures

• SOP’s are step-by-step flow charts showing reliable methods for completing tasks

• Warning boxes show hazards that need to be avoided during tasks

On-The-Job Risk Assessments

• Job Performance Safety Analysis– Group discussion of project or task

• Pocket Cards– Individual-based reminder card

• Behavior-Based Safety Observations– One-on-one discussions

• Vehicle/Crane/Tool Inspections– Looking for hazards every shift

Team Members Help with Audits

• VPP Audits• Key Element Survey Audits• Wall-To-Wall Conditions Audits• Winder Audits• Housekeeping Audits

Mill-Wide Communications

• Incident Flashes– Documented within 24 hours of incident– Distributed using several modes

• Email• Morning leadership meetings• Bulletin Boards• Preshift meetings for process and maintenance teams• Entered in database for corporate distribution

Incident Flashes

• One page document to show what, when, and where

• Printed on yellow paper and posted in main hallway

• Lists immediate corrective actions to be taken• Does not include names of people involved in

incident• How & why determined in investigations

• Incident Investigations– Conducted by trained team members– Reports distributed as widely as flashes– Significant investigations include power point

presentation for quicker & easier description of incident as well as communicating root causes and corrective actions company wide

Corrective ActionsAction Responsibility Completion DateFollow up with carrier to ensure all drivers are receiving proper training and safety information

John Doe 4/15/13

Per IP policy, driver banned from mill site for 24 hours.

John Doe 3/29/13

Meet with carrier to discuss incident. Jane Doe 4/12/13

Share incident with all carriers. Jane Doe 4/12/13

• Contractor Meetings– Monthly meetings with on-site contractors– Quarterly meetings with safety and leadership

representatives from all contractors• Held the day before a major maintenance outage• Review of safety performance• Review policies and procedures• Discuss changes and updates on hazard prevention

• A Wide Variety of Visuals– Posters and Bulletin Boards– Hazard labels– Warning signs– Danger & caution tape with barricade tags– Yellow paint on steps– Black and yellow floor stripes near winder– Stripes for crane use near reel

EHS&S February 21, 2013

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In 2010 International Paper launched the LIFE initiative, a multi-year effort to identify and mitigate the potential

hazards and risks that lead to serious injuries and fatalities.

LIFE Definition

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What is a LIFE Incident?

A fatality or amputation

OR

An injury that results in 14 or more calendar days away from work and involves:

• Organ Damage• Concussion or Other Brain Trauma• Bone Fracture

• Crushing Injury• Degloving• Serious 2nd or 3rd Degree Burn

28%

18%10%

23%

23%

2012 Employee LIFE IncidentsMachine Safeguarding

Falls

Motorized Equipment

Harmful Substances or Environments

Driver SafetyOther*

2012 LIFE Incidents

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*Other – Primarily struck by or caught between objects

LIFE Lessons

• One-page summaries of LIFE incidents are shared among company sites to allow all employees in International Paper to learn from each incident.

• A picture, brief summary, root causes, and corrective actions are included in the lesson.

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5 LIFE Focus Areas anda New Contractor Safety Emphasis

Machine Safeguarding

Motorized Equipment

Falls

Exposure to Harmful Substances or Environments

Driver Safety

Contractor Safety New for 2012

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How do we get there?

Identify & Eliminate Hazards

Individual Accountability Look Out for Others Intervene When

Needed

“Management is doing things right;leadership is doing the right things.”

-Peter Drucker

Local LIFE Initiative Work

• Traffic flow analysis and controls• Machine guarding inventory and

improvements• Cell phone policy implementation

Driver Safety-Cell Phones

Absolutely no cell phone use when driving:-in company vehicle-in company-rented vehicle-in any vehicle on company property-including any powered industrial truck-in private vehicle on company business

Her last call was from a cell phone.

Combinations of Hazards

• What do we get when unsafe behavior A intersects with unsafe behavior B in time and space?

At an estimated 85 mph, the motorcycle driver could not react when the automobile driver on a cell phone pulled out from side

street.

More IP employees work safely today than ever before ...

• 70% improvement in TIR since 2000

• IP leads the paper industry in safety

• Many facilities are working injury-free

… but there is more work to do

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• Numbers show downward trend in recordable injuries

Safety is not about numbers.

It’s about our health and well-being … it’s about our teammates…

it’s about friends…It’s about family…

…and our ability to go home safely to them

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