Total Injuries at ProjectJan 2005 to date
3 3 3
57
12
2422
20
46
9
3 312112 20
10
20
30
40
50
60
Jan-05
Feb-05
Mar-05
Apr-05
May-05
Jun-05
Jul-05
Aug-05
Sep-05
Oct-05
Nov-05
Dec-05
Jan-06
Feb-06
Mar-06
FA
MA
78
13
48
ZERO Lost Time Incidents
45.1 45.1
20.8
29.9 30.5
38.8
52.0 50.949.1
65.1
55.0
48.8
0
10
20
30
40
50
60
70
80
90
Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05
YTD Accumulated Hours (X 10,000)
Monthly Hours (X 1,000)
Total Incident Frequency Rate
Company on Major Projects2005
Company on Major Projects2005
45.1 45.1
20.8
29.927.1
36.3
50.3 49.748.2
54.1
46.5
41.4
0
10
20
30
40
50
60
70
80
90
Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05
YTD Accumulated Hours (X 10,000)
Monthly Hours (X 1,000)
Total Incident Frequency Rate
With 52C Plant Start-up “Exposures” removed….
0
10
20
30
40
50
60
70
80
90
Month
Recordable Incident Rate
Total Incident Freqency Rate
Weekly Hours (X 1,000)
Project MTIFR: 37.9
Rebuild TIFR: 27.33
Company Hours & Incident RatesLast 2 Years
0
10
20
30
40
50
60
70
80
90
Month
Recordable Incident RateTotal Incident Freqency Rate
Weekly Hours (X 1,000)
Project Millennium TIFR: 37.9
Suncor 52C Fire Rebuild TIFR: 27.33
Company Work Hours & Incident RatesLast 2 Years
With Plant Start-up “Exposures” removed….
Oct 6th : M
eeting With Client
Oct 14th : Zero Tolerance Adopted
Oct 15th : Functional Safety Plan
Oct 19th : Aggressive A&D Policy
Oct 20th : Fresh Start /
Stand Down
Oct 25th : S
afety Incentive Program
Nov 24th : 2
nd Stand Down/Follo
w-Up
Nov 23rd : 1
st Safety Committe
e Insp
.
Nov 14th : 1st Safety Committe
e Mtg.
Mar
14
th : “Rem
embe
r Cha
rlie”
Feb 1
4th : I
nter
nal A
udit S
tart
(12 month moving TRIR)
Lessons Learned Lessons Learned
and and
2006 Improvement 2006 Improvement
PlanPlan
Things To Do:
0
10
20
30
40
50
60
70
80
90
Feb
-04
Mar
-04
Apr
-04
May
-04
Jun-
04
Jul-0
4A
ug-0
4S
ep-0
4O
ct-0
4N
ov-0
4D
ec-0
4Ja
n-0
5F
eb-0
5M
ar-0
5A
pr-0
5M
ay-0
5Ju
n-0
5
Jul-0
5A
ug-0
5S
ep-0
5O
ct-0
5
Nov
-05
Dec
-05
Jan-
06
Feb
-06
Mar
-06
Month
Recordable Incident RateTotal Incident Freqency RateWeekly Hours (X 1,000)
• Difficult to identify high-risk workers.
• Many low-experience workers (many competing projects).
• New Workers = New Foremen
IDENTIFYING HIGH-RISK WORKERS
SAFETY INTERVENTION PROGRAM MENTOR PROGRAM
LOW EXPERIENCE
WORKERS
CREW DISTRIBUTION
MORE INCIDENTS = MORE
INVESTIGATIONS
SUPERVISOR – INCIDENT INVESTIGATION
TRAINING
NEW WORKERS =
NEW FOREMEN
FOREMAN ORIENTATION TRAINING
REPORTS BY SUPERVISOR / IDENTIFY
TRENDS
-Intervention Program
-Mentor Program -Investigation Training
-Foreman Orientation
0
10
20
30
40
50
60
70
80
90
Feb
-04
Mar
-04
Apr
-04
May
-04
Jun-
04
Jul-0
4A
ug-0
4S
ep-0
4O
ct-0
4N
ov-0
4D
ec-0
4Ja
n-0
5F
eb-0
5M
ar-0
5A
pr-0
5M
ay-0
5Ju
n-0
5
Jul-0
5A
ug-0
5S
ep-0
5O
ct-0
5
Nov
-05
Dec
-05
Jan-
06
Feb
-06
Mar
-06
Month
Recordable Incident RateTotal Incident Freqency RateWeekly Hours (X 1,000)
• Fatigue a possible factor.
0
10
20
30
40
50
60
70
80
First 2 months 3rd and 4th Month 5th and 6th Month After 6th Month
Time From Hire Date
Nu
mb
er
of
Inju
rie
sInjuries from Hire Date2005
• 60% Currently Trained
• 84% End of April
• 100% End of May
Supervision Training
2005 Nature of Injury
34%
2%12%15%1%
1%
23%
7%
1%
1%
1%Sprain / Strain
Puncture
Laceration
Illness
Hemmorage
Fracture
Foreign Body
Contusion
Break
Blister
Abrasion
2005 Incident-Specific Lessons Learned
DEVELOP AND COMMUNICATE SAFE MANUAL MATERIAL HANDLING JHA
COMBINED = 50%BULK ARE PRECEDED BY “CRITICAL ERRORS”:
• EYES ON TASK• MIND ON TASK• LINE OF FIRE
WILL BE ADDRESSED WITH INTRODUCTION OF BBS
TRAINING WITH FRONT-LINE SUPERVISION:ENSURE ADEQUATE MANPOWER FOR TASKS
ENSURE ROTATION OF WORKERS
34%
2%
12%15%1%
1%
23%
7%
1%
1%
1%Sprain / Strain
Puncture
Laceration
Illness
Hemmorage
Fracture
Foreign Body
Contusion
Break
Blister
Abrasion
SPRAINS / STRAINS
34%
MATERIAL HANDLING
35%
BALANCE / TRACTION / GRIP
27%
STRUCK BY / AGAINST
23%
OVER EXERTION / REPETATIVE STRAIN
15%
Things To Do:
-Roll out B.B.S.
-Add job rotation to Supervisor Training
34%
2%
12%15%1%
1%
23%
7%
1%
1%
1%Sprain / Strain
Puncture
Laceration
Illness
Hemmorage
Fracture
Foreign Body
Contusion
Break
Blister
Abrasion
FOREIGN BODIES
23%
PRIMARILY IN EYES
FIRST INCIDENT REPORTED IN JUNE
EYE PROTECTION AWARENESS
CAMPAIGN TO BE LAUNCHED IN MAY
EDUCATION
EXPECTATIONS
SUPERVISION
WORKERS
ACCOUNTABILITY
Things To Do:
-Roll out eye protection campaign in May
34%
2%
12%
15%
1%
1%
23%
7%
1%
1%
1%Sprain / Strain
Puncture
Laceration
Illness
Hemmorage
Fracture
Foreign Body
Contusion
Break
Blister
Abrasion
ILLNESS15%
PRIMARILY EXPOSURE
ALL INCIDENTS BETWEENSEPT 22ND AND OCT 19TH
DURING RAMP UP OF PLANT
SHOULD BE ONE TIME ISSUE
SIMILAR FUTURE SITUATIONS
FORWARD LOOKING
EDUCATION
WORK WITH CLIENT TO ENSURE WORKFORCE
EDUCATED AND PROPER PROTECTIVE
MEASURES ARE TAKEN
Things To Do:
-Build training to roll out before next startup phase.
INEXPERIENCED WORKERS
34%
2%
12%
15%1%
1%
23%
7%
1%
1%
1%Sprain / Strain
Puncture
Laceration
Illness
Hemmorage
Fracture
Foreign Body
Contusion
Break
Blister
Abrasion
LACERATIONS12%
CONTACT WITHSHARP EDGE
38%
HANDLING SHARPMATERIALS
31%
STRUCK BY / AGAINST
15%
CONTACT WITHKNIFE BLADE
7%
EYES ON TASK / MIND ON TASK /
LINE OF FIRE
BEHAVIOUR BASED SAFETY
POOR PRACTICE
EDUCATION
EXPECTATIONS
SUPERVISION
WORKERS
ACCOUNTABILITY
0.000
0.010
0.020
0.030
0.040
0.050
0.060
0.070
0.080
0.090
Jan 7 Jan 14 Jan 21 Jan 28 Feb 4 Feb 11 Feb 18 Feb 25 Mar 4 Mar 11 Mar 18 Mar 25
Week Ending
# o
f F
LH
A's
pe
r H
ou
rField Level Hazard Assessments
Attitudes & Behaviour Eliminate All Risk
Self95%
Other People4%
Equipment1%
•Rushing•Frustration•Fatigue•Complacency
•Eyes not on task•Mind not on task•Line-of-fire•Balance, traction, grip
Major
Minor
Close Calls
Hazards
Major
Minor
Close Calls
Hazards with a Critical Error
SAFETY INCENTIVE PROGRAMSAFETY INCENTIVE PROGRAM
Safety Awards at Safe Work Hour Milestones
Communicate at Hire
Has Raised Awareness Toward Small Incidents
2nd Phase (Specific Act Rewards) Rolling Out Soon
Identifies workers that have had 2 or more injuries within one year; or 1 incident within the first month.
Safety awareness discussion Incident history review Incident frequency projection (“If you continue at this rate…”) Hazard recognition and personal responsibility Increase personal awareness of safety performance Worker-driven action plan
Hazard recognition training
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