Improving safety in the industry:
CSI progress and priorities
CSI Forum 2009
Antony Henshaw
CEMEX / CSI
Background: Health and Safety
• 1 of 6 key areas identified in Agenda for Action
• CSI member commitments (2002):
– develop standard, joint systems to measure, monitor and
report
– establish information exchange to share experiences and
understand accident root cause
– improve existing systems, procedures and training for
tracking, following up and preventing accidents
– report performance publicly in common format
2
Work to date
‘Guidelines for Measuring
and Reporting’
‘Examples of
Good Practice’
3
Key Performance Indicators
KPI’s (Cement only)
Year 2003
Year 2004
Year 2005
Year 2006
Year 2007
Year 2008
CSI Members reporting
11
14
16
18
17
18
130,752
138,940
148,684
172,133
188,834
190,747
Manhours, directly employed
246m
269m
286m
372m
402m
390m
LTIs, directly employed
1,651
1,585
1,699
1,381
1,301
1,038
LTI FR, directly employed
6.71
5.88
5.95
3.71
3.23
2.66
Number of Lost Days (calendar),
directly employed
No data
No data
69,074
67,035
59,949
70,566
LTI SR (calendar), directly
employed
No data
No data
242
180
149
181
Number of LTIs, indirectly
employed (contractors)
652
739
835
1,199
1,285
1,122
Number of Fatalities, directly
employed
28
27
22
25
33
26
Fatality Rate (per 10,000
directly employed)
2.14
1.94
1.48
1.45
1.75
1.36
Number of Fatalities, indirectly
employed (contractors)
32
54
41
58
87
91
Number of Fatalities, third parties
21
11
12
6
11
16
Total number of Fatalities
81
92
75
89
131
133
Total directly employed
4
Good progress in LTIs reduction
8
Frequency Ratio
7
6
5
4
3
2
1
2003
2004
No Data
No Data
0
2003
2004
2005
2006
2007
2006
2007
Severity Ratio Calendar
300
250
200
150
100
Data here: cement-only
LTI data for all activities
shows similar
positive downward
trend
50
0
2005
5
Poor progress on fatality reduction
2008: 220 reported fatalities
9%
Activity
2007
2008
Cement
134
133
Aggregates
15
22
Readymix
Readymix
33
45
Other
Others*
25
20
207
220
Cement
20%
Aggregates
61%
10%
Totals
CSI fatality incidence is unacceptable
6
Fatality rates: cement-only

2008: 133 cement-only fatalities (16 employee, 102 contractor, 15 third party)

Similar total to 2007

Reduction in employee fatalities offset by increase in contractor fatalities
120
Third Party
Contractor
Employee
# Companies Reporting
20
18
16
# Fatalities
100
14
12
80
10
60
8
6
40
4
20
2
0
0
2003
2004
2005
2006
2007
2008
37
# Companies
140
Peer comparison
Employee Fatality Rates
Fatality Rate
2
1.5
1
0.5
0
OGP
Chem
CSI
Contractor Fatality Rates
16
Fatality Rate
14
12
10
8
6
4
2
0
OGP
CSI
(CSI contractor rate is estimated)
• Cement industry
performance very poor
compared to the Chemical
and Oil & Gas industries
• Despite good practice
sharing and ongoing safety
commitments fatality
rates are rising
• Likely to increase as CSI
members expand into
developing regions and
construct new plants
38
Peer comparison: fatality prevention
Fatality Prevention Review (2009):
31 companies consulted
Focused on fatality prevention statistics and
approaches to ascertain:
– Best-performing companies
– How they achieve success in fatality elimination
– What the CSI can learn
11
Fatality rates
“Class A”
“Class B”
“Class C”
“Class D”
“Class E”
Employee
Fatality Rate
of < or = 0.1
Employee
Fatality Rate
of 0.11 to 0.25
Employee
Fatality Rate
of 0.26 to 0.5
Employee
Fatality Rate
of 0.51 to 1.0
Employee
Fatality Rate
of 1.01 to1.5
Akzo Nobel
CAT
Continental
Exelon
Fortum
GE
ITT
Mondi
Pirelli
UTC
ABB
AEP
BP
Dow
Shell
Umicore
Alcoa
DSM
ENI
EvonikDegussa
Petro-Canada
Rio Tinto
Weyerhaeuser
Alstom
Goodyear
Hoegh
Stora Enso
TNT Express
AngloAmerican
BHP Billiton
EON
OGP
CSI
If CSI moved to “Class A” it could save up to
200 lives a year
12
Learning for CSI
• 70% have specific Fatality Prevention
initiatives
• Successes:
– UTC & Rio Tinto reduced fatalities by factor of
10
– ABB by factor 7
– AEP by factor of 5
• Successes typically gained over 5 years,
some 3 years
13
Key success factors







Highly visible CEO commitment
Senior Management safety training
Establishing safety “Golden Rules”
Strong safety management of contractors
Strong safety management of drivers
Rigorous fatality investigation procedures
Implement specific fatality prevention focus
14
CSI: Root case analysis
Highest risk category of person: contractors
Category
2007
2008
19%
20%
Employee
Employee
45
42
Contractor
Contractor
122
133
Third Party
Third Party
40
45
207
220
61%
Totals
15
Root case analysis
4%
2%
6%
3%
Traffic & Moblie Plant
Falls from Height & Items
Falling
9%
47%
Caught in Moving/Starting
Equipment
Electrocution during plant
maintenance
Buried in Stockpile/Silo
Explosion of tanks & tankers,
Fires
Other
29%
Highest risk area of work: driving and vehicles
16
CSI action
Driver and Contractor Safety Initiatives
started in November 2008
To eliminate driver and contractor
related injuries and fatalities
17
Driver and Contractor Safety
Driver Safety guidelines:
– 8 Safety Elements for Drivers
– 9 Safety Elements for Managers
– Guidelines on Implementation of Safety
Elements
– Guidelines for Transport Contractor
Management
18
Driver and Contractor Safety
Contractor safety guidelines:
– Safety Considerations for Contractor
Management (Prequalification, Contract Definition
and Award, Pre-Commencement, Implementation,
Handover and Acceptance, Post-Contract Review)
– 6 Safety Elements for Contractor
Management:
– Guidelines on Implementing Safety
Elements for Contractor Management
19
Implementation
• Gap analysis by each CSI member company
on systems already in place
• Adoption of Good Practice documents within
5 years across all activities and regions
• Public updates on implementation progress
20
Pilot projects (contractors)
• Overseen by individual companies
• Review success in near future and assess
CSI-implementation potential
– USA (contractor prequalification)
– Poland (contractor employee passports)
21
Key messages
• CEO-led initiative, expecting their
approval and leadership
• Our injury performance as an industry is
far from where we need it to be
• Without focused prevention initiatives we
can expect our performance to worsen
• Industry support for the Driving and
Contractor Safety Management
documents will set us on the right path to
zero fatalities
22
For more information …
Driver Safety breakout session:
This afternoon at 16.15
Chromium room
Task Force Co-Chairs:
Jim O’Brien: [email protected]
Paul Corbin: [email protected]
www.wbcsdcement.org/safety
23
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