Introduction to DuPont Safety Principles&PPD Safety Audit Program :August 8, 2007 Version 3.3 1 Introduction to DuPont Safety Principles&PPD Safety Audit Program Safety management Created By Rajesh Samkaria Bhopal


Safety process :August 8, 2007 Version 3.3 2 Safety process “You get the level of safety that you demonstrate you want.” (DuPont Proverb)


Outline :August 8, 2007 Version 3.3 3 Outline Principles of DuPont’s approach to safety Overview of PPD’s Audit Program Details of PPD’s Audit Program Forms and examples


DuPont core belief :August 8, 2007 Version 3.3 4 DuPont core belief All injuries can be prevented


Benefits of Good Safety Management :August 8, 2007 Version 3.3 5 Benefits of Good Safety Management Reduction in the cost of medical and workers’ compensation Greater productivity Improved product or research quality Overall operation improvement


Basic Principles of Good Safety Management :August 8, 2007 Version 3.3 6 Basic Principles of Good Safety Management Management Commitment Documented Safety Philosophy Safety Goals and Objectives Committee Organization for Safety Line Responsibility for Safety Supportive Safety Staff


Basic Principles of Good Safety Management (cont’d) :August 8, 2007 Version 3.3 7 Basic Principles of Good Safety Management (cont’d) Rules and Procedures Audits Safety Communications Safety Training Accident Investigations Motivation


DuPont’s Experience :August 8, 2007 Version 3.3 8 DuPont’s Experience A ten-year study of all serious injuries occurring across all Du Pont sites showed that: 96% of the injuries resulted from the unsafe acts of people or from poor work practices Only 4% of the injuries resulted from unsafe conditions


DuPont’s Expectations for Safety Performance :August 8, 2007 Version 3.3 9 DuPont’s Expectations for Safety Performance Employees must: Make safety equal to all other aspects of the job [and in PPD, safety is #1] Follow all safety rules and procedures Management must: Accept responsibility for prevention of injuries Accept responsibility for safety training


Supervisor’s Responsibilities :August 8, 2007 Version 3.3 10 Supervisor’s Responsibilities Know, communicate, and enforce existing standards Recognize the need for revised standards Develop new procedures and rules when necessary Train employees to follow all rules and procedures


ES&H Responsibilities :August 8, 2007 Version 3.3 11 ES&H Responsibilities Serve as advisors when addressing supervisors’ questions arising from audits Perform audits as a crosscheck of the audits conducted by line management Help to address safety issues uncovered in audits Compile, analyze and disseminate data collected from the audits


Overview of PPD’s Audit Program :August 8, 2007 Version 3.3 12 Overview of PPD’s Audit Program


PPD’s Audit Program :August 8, 2007 Version 3.3 13 PPD’s Audit Program An opportunity to spend a few minutes observing activities in the workplace and then discuss what you’ve seen with your employees This is done with an eye towards safe, and unsafe, behavior Mitigate hazards Record observations


Proposed auditing in AD areas during the shutdown :August 8, 2007 Version 3.3 14 Proposed auditing in AD areas during the shutdown The main focus of today’s training is the situation where a supervisor is auditing his or her people in their normal work areas It is likely that PPD supervisors will be asked to conduct safety audits of their people who are working in Accelerator Division areas during the shutdown Audits in AD areas will be conducted in a similar fashion to those in PPD areas


Slide 15:August 8, 2007 Version 3.3 15


:August 8, 2007 Version 3.3 16 Inspection versus Things Passive Experts (them) Negative Document / Follow up Audit People Interactive (I care) Everyone (us) Positive & Negative Document / Follow up DuPont’s nomenclature


Purpose of PPD’s Safety Audit :August 8, 2007 Version 3.3 17 Purpose of PPD’s Safety Audit Identify safe and unsafe, acts or conditions Identify areas for improvement Follow up when mitigating actions are indicated Accumulate data for tracking trends related to safety


Types of safety audits :August 8, 2007 Version 3.3 18 Types of safety audits Scheduled Unannounced Compliance with standards Adherence to procedures


Benefits of safety audits :August 8, 2007 Version 3.3 19 Benefits of safety audits Promote safe behavior Test for compliance with standards Establish standards Identify weaknesses Accumulate data Prevent injuries


Who conducts PPD safety audits? :August 8, 2007 Version 3.3 20 Who conducts PPD safety audits? Division Office Department Heads Group Leaders Supervisors ES&H Staff Project Management


Proposed frequency of audits :August 8, 2007 Version 3.3 21 Proposed frequency of audits Division Office – Quarterly Department Heads, Level 1 Project Managers – Quarterly Group Leaders, Level 2 Project Managers – Monthly ES&H Staff – Monthly Supervisors, Level 3 Project Managers – Weekly


Where are audits conducted? :August 8, 2007 Version 3.3 22 Where are audits conducted? Wherever your employees are working Group work areas Individual work spaces


Auditing :August 8, 2007 Version 3.3 23 Auditing Focus on one or two activities One location or portion of a building One or two processes Plan for a duration of an hour or less


Details of PPD’s Audit Program :August 8, 2007 Version 3.3 24 Details of PPD’s Audit Program


Elements of our Safety Audit Process :August 8, 2007 Version 3.3 25 Elements of our Safety Audit Process Read the Audit Checklist prior to the walkthrough Visit the work area and talk with employees (without paperwork in hand) Mitigate any unsafe situation After the walkthrough: Complete the checklist and the Audit Form Follow up, if necessary


What to look for during an audit :August 8, 2007 Version 3.3 26 What to look for during an audit Reactions of people Positions of people Personal Protective Equipment (PPE) Tools and equipment Procedures Housekeeping


What to look for during an audit (cont.) :August 8, 2007 Version 3.3 27 What to look for during an audit (cont.) Reactions of people Does anyone adjust PPE, change position, or rearrange job when the safety auditor appears? Does anyone abruptly stop work, attach grounds, or perform LOTO? Positions of people Is anyone in danger of injuring himself by pulling or lifting heavy objects? Is anyone in a position where he or she could fall, be trapped, collide with anything, or be hit?


What to look for during an audit (cont.) :August 8, 2007 Version 3.3 28 What to look for during an audit (cont.) Personal Protective Equipment (PPE) Are employees using the required protective equipment? Are they using the PPE properly? If not, why not? Is the PPE inconvenient to obtain or hampering the job in some way?


What to look for during an audit (cont.) :August 8, 2007 Version 3.3 29 What to look for during an audit (cont.) Tools and equipment Are they being used properly? Are they in safe condition? Are homemade tools (not properly designed) being used? Procedures Are they adequate? Do they prevent all unnecessary risks? Are they followed?


What to look for during an audit (cont.) :August 8, 2007 Version 3.3 30 What to look for during an audit (cont.) Housekeeping Is the workplace neat? Are things put away properly?


Safety Audit Checklist :August 8, 2007 Version 3.3 31 Safety Audit Checklist Safety Audit Checklist Handout


The Safety Audit Form :August 8, 2007 Version 3.3 32 The Safety Audit Form


The Safety Audit Form :August 8, 2007 Version 3.3 33 The Safety Audit Form


The Safety Audit Form :August 8, 2007 Version 3.3 34 The Safety Audit Form


The Safety Audit Form :August 8, 2007 Version 3.3 35 The Safety Audit Form Potential Injury Severity


When Someone is Working Unsafely :August 8, 2007 Version 3.3 36 When Someone is Working Unsafely Observe; then get the person’s attention Comment on what the employee was doing safely Discuss with the employee The possible consequences of the unsafe act Safer way to do the job


When Someone is Working Unsafely (cont’d) :August 8, 2007 Version 3.3 37 When Someone is Working Unsafely (cont’d) Get the employee's agreement to work safely in the future Discuss other safety issues of the job Ask the employee what you the supervisor could do to make the employee’s job safer Thank the employee


Audit Examples :August 8, 2007 Version 3.3 38 Audit Examples


Audit Examples :August 8, 2007 Version 3.3 39 Audit Examples


Audit Example :August 8, 2007 Version 3.3 40 Audit Example


Audit Examples :August 8, 2007 Version 3.3 41 Audit Examples


What happens to the safety audit sheets? :August 8, 2007 Version 3.3 42 What happens to the safety audit sheets? PPD/ES&H ESHTRK Statistics


Conclusion :August 8, 2007 Version 3.3 43 Conclusion All injuries can be prevented Management is responsible for preventing injuries Working safely is a condition of employment Training employees to work safely is essential Prevention of personal injuries is good business (and good science!) Audits can play a key role in safety And, once again …


PPD’s Audit Program :August 8, 2007 Version 3.3 44 PPD’s Audit Program An opportunity to spend a few minutes observing activities in the workplace and then discuss what you’ve seen with your employees This is done with an eye towards safe, and unsafe, behavior Mitigate hazards Record observations