Workshop V

Enhancing Workplace Safety Through People …

Applying the Team Activity Plan Concept

Tuesday, March 27, 2012 3:30 p.m. to 4:45 p.m.

Biographical Information

Deidre L. Tate, Process Safety Specialist Chilworth Technology, a DELRA Company, 113 Campus Dr., Princeton, NJ 08540

[O]: 609-799-4449 [M]: 732-895-0602 [F]: 609-799-5559 dtate@chilworthglobal.com deidre.tate@dekra.com

Deidre Tate, B.S., MBAc, CHWM, comes to Chilworth with more than 20 years of experience in the chemical and pharmaceutical manufacturing industries. This includes 15 years in senior leadership roles at the facility & corporate levels. Deidre’s previous experience includes EHS Program Coordinator at Wayne State University in Detroit, MI, EHS Administrator at AlliedSignal in Troy, MI, NAFTA Environmental Mgr. at Syngenta Crop Protection in DE, NC & TX, PSM Coordinator at Marathon in MI and EH&S Manager for JM Pharmaceutical Materials in NJ & PA. Deidre is also a Master Trainer, having delivered more than 10,000 hours of technical training. She has managed numerous PSM and RMP programs, emergency response and remediation activities, and has led process hazard analysis, risk assessments and JSA’s. She has created PSM, Quality, Chemical Security and EHS integrated management systems including VPP, Responsible Care, OHSAS 18001, and ISO 14001. Deidre is a graduate of Michigan State University with a B. S. from the College of Agriculture & Natural Resources and received a graduate certificate from the College of Engineering at Wayne State University in Hazardous Waste Management. She also has received several certifications which include: Asbestos Abatement Instructor, Management Planner & Inspector; Environmental MBA, ISO-14001 Internal Auditor, RCRA, HAZWOPER, & DOT Trainer.

Sustainability and EH&S Symposium

March 27, 2012March 27, 2012

Enhancing Workplace Safety Through People…. Applying the Team Activity Plan Concept

(TAP)(TAP)

Presented byyDeidre L. Tate, CHWM

Chilworth Global

About Chilworth Global(A DEKRA Company)

A worldwide leader in process safety p yservices providing a full array of Process Safety Engineering (PSE) and Process Safety Managementand Process Safety Management (PSM) services including: management consulting, training,

’ S /PHA’s, PSM/RMP audits, incident investigations, laboratory testing of combustible dust, thermal stability, , y,reactivity, process design, safety engineering support and expert witness and litigation supportwitness and litigation support.

DEIDRE L. TATE, CHWM

Employee Participation Plan

Wh t If

Dept. MeetingsEHS CommitteeSOS M ti Ti 1What-If

DrillsSOS Meetings

Monthly EHS MeetingsTier 1

EHS Audits

TAPTeam Activity

Plan

JHAsLearning

EventTraining

&Observations Metrics

P ti i ti T ki W k h tParticipation Tracking Worksheet

Why Was TAP Implemented ?

3 Corporate Mandates ISO-14001Learning Events

Compliance GapsEmp. Participation

Contractors

PSM Compliance

E i l R li bili

Learning EventsSustainability

ContractorsTrainingSOP’s

Environmental Reliability

Plant CultureTitle V $$$$NJ DPCC

Needed To Build A Team Culture

t

Plant Culture Transition

• Liberating and developmental• Control, achievement &

continuous improvement oriented Staf

f

anag

emen

t

Theo

ry Y

pby enabling, empowering and giving responsibility

Douglas McGregor’s XY- Theory

Ma

• Authoritarian, repressive style• Tight control, no development• Produces limited, depressed

ltgem

ent

Staf

f

ory

X

culture

Man

ag S

The

Source: 2002 Alan Chapman Based on D. McGregor’s XY Theory. www.businessballs.com

Inherited Plant Culture

Summary

OUR OBJECTIVES

• Transition from an X culture to a Y culture

• Eliminate silos

• Empowerment & Accountability

Plant CultureRebuild

RelationshipsRelationships between EHS, Ops &

Site LeadershipIncrease

Employee Level

Transition to a Team Culture

Employee Level Of Involvement

PERFORMANCE MEASURES

EHS&S Management Framework

Vision: Continuously Improve Environmental, Health, Safety & Security Aspects Our Operations And Products

Organizing Principles(How we organize our strategy)

Building Blocks(Steps necessary to achieve our vision)

Shift F F R ti T P tiStrategy Shift Focus From Reactive To Proactive(over the entire EHS&S Management System)

Strategy(How we achieve our vision)

Summary

Corporate Mandatesp

PERFORMANCE MEASURES

Implement SustainabilityInitiative within 6 months

OUR OBJECTIVES

• Find a way to launch initiatives without overwhelming operations & EHS Staffoverwhelming operations & EHS Staff

Drivers For Corporate InitiativesDrivers For Corporate InitiativesBehavioural causes: Working environment causes:• Body mechanics (30)• Eyes on task (18)• Eyes on path (17)• Inappropriate PPE (7)

• Unsafe work practice (27)• Inherent hazard (16)• Lack of equipment (8)• No equipment cause (8)• Inappropriate PPE (7)

• Work-around (7)• No behavioural cause (6)• Unknown (4)

• No equipment cause (8)• Ineffective safety device (7)• Unknown (7)• Equipment positioning (6)( )

• Deliberate violation (1)q p p g ( )

• Poor housekeeping (5)• Mechanical failure (4)• Insufficient fault-tolerance (2)

Conclusion: It is important to target both behaviours and problems in the working environment to reduceand problems in the working environment to reduce

accident frequency

EHS Learning Events: an analogyEHS Learning Events: an analogy• Working in industry is a bit like swimming in a shark-infested sea

– Workers are like the swimmers– Sharks are like the risks

• There are two realistic strategies that stop the sharks eating the swimmers1. Show the swimmers how to avoid the sharks2. Identify and remove the sharks

• you need a system that both helps the swimmers identify the sharks• … you need a system that both helps the swimmers identify the sharks and flags the sharks so they can be removed

EHS Learning Event Observations

Aim:Influence employee behavior throughInfluence employee behavior through increased reporting of low-level events and conditions

Objectives:• Encourage employees not to adopt at-risk g y

behaviors• Learn more about issues within the working

environment and make improvements beforeenvironment and make improvements before accidents happen

SummarySummary

PSM CompliancepIMPORTANT:

- Real Risks SOP’sContractors

Gaps in:

Pending PSM Audit

ContractorsTraining

Emp. Participation

MOC MI

PERFORMANCE MEASURES

- High Visibility within the CompanyMOC, MI

PHA

OUR OBJECTIVES

• Ensure compliance with effective management systemmanagement system

• Engage “all” employees in efforts

D i t th l ti hi b t

Safety Incident Pyramid Applied to Process Safety

• Depicts the relationship between the incident severity and frequency

• Top of the pyramid indicators are more “lagging” or outcome / results oriented

• Lower tiers of the pyramid are “leading” indicators of performance at higher tiers, p g ,resulting in a continuum of leading and lagging indicators

• Bottom of the pyramid indicators are• Bottom of the pyramid indicators are more “leading” or predictive in nature

Summary

OUR OBJECTIVES

• Maintain license to operate

• Find a self-directed way to empower employees to correctly identify & correct operating conditions which lead to permit violations

Environmental Reliability

Implement Verification of Compliance Thru

Increased Inspections

PERFORMANCE MEASURES

Training & Learning MgtTraining & Learning Mgt.New Job Specific Training Added Minimum Requirements For

• PHA Leader & Team MemberO & SS

p g& Incorporated Into A Learning Management System

New Employee Training:

• Site EH&S Hazards • Protective Measures• Operating Limits & SSMP

• MOC• Self-inspections• RCA for Incident Investigation

Protective Measures• Emergency Evacuation• OSHA HAZCOM & RTK• PSM & Chemical Security Awareness• RCA for Incident Investigation

• Job Hazard Analyses, etc.• DOT HAZMAT• HAZWOPER

y•ISO 14001 Fundamentals• GMP (Quality)•TAPHAZWOPER •SharePoint, eDoc & Trackwise

SharePoint Example

Review of TAB Benefits

• TAP develops consistency

The process is applied consistently across the facility.

TAP i Th D t t EHS M ti t t f• TAP improves communication

The Department EHS Meetings use a strategy of flowing information from the ground level to management in sequence, ensuring employee concerns are addressed and not lost.co ce s a e add essed a d o os

• TAP develops accountability

The application of the process is measurable

TAP i I d t it EHS diti & ff ti• TAP increases our knowledge

In regards to site EHS conditions & effectiveness of initiatives

• TAP develops employee Delivering EHS meetings, JHAs, “What-If” Drills &I ti i h d iti &involvement Inspections increases hazard recognition & fosters employee confidence.

• TAP enables all l t b

This is a requirement for high EHS performance & performance based regulatory programs likeemployees to become

Champions within the EHS process

& performance based regulatory programs like PSM and voluntary certifications (VPP, ISO, RC, OHSAS, etc.)

QUESTIONS?QUESTIONS?

Deidre L. Tate, CHWMProcess Safety Specialist

dtate@chilworthglobal.com(O): 609-799-4449(M): 732-895-0602