A 19-Year Case Study
On Tuesday, August 18, 2020, from 4:15 to 4:45 PM, I will be making a virtual presentation at the AiCHE 16th Global Congress on Process Safety. The paper is a 19-year case study demonstrating a successful plant leadership transition that improved process safety performance.
When I was transferred to the DuPont Belle, West Virginia plant in 1987, the Total Recordable Injury Case Rate (TRC) was about 5.8 and emissions to air, water and ground, as reported in the EPA Toxic Release Inventory (TRI) annual report, was over 6,000,000 pounds/year. Within three years, both of these had dropped by about 95% to a TRC of about 0.3 and a TRI of about 275,000 pounds/year. Emissions to the environment is one way to measure how well the process safety is working; the better the process safety work, the lower the emissions to the environment.
I was using a highly, participative leadership process I called Partner-Centered Leadership for Occupational Injuries and Health, as well as for Process Safety; this was a highly integrated process with just about everyone involved, and consciously working together to make our plant safer and have less impact on the environment. When I was transferred by DuPont in 1995 and replaced by a traditional plant manager using a top-down driven management process, things changed.
The process safety work was pulled away from the occupational safety and health effort and taken over by the managers. The occupational safety and health work continued to be led by the first and second level supervisors using the Partner-Centered Leadership approach. The highly participative leadership approach and the top-down management approach were running in parallel (the same business conditions, the same regulatory pressures, the same people, the same community). The occupational safety and health performance stayed at a rate of 0.3 or better for the next 15 years.
But the five different plant managers who came in during that period gradually cut back the process safety management resources and effort. They cut back on the manpower, allowed work-orders to pile up, stretched out the inspection intervals, ignored feedback from the operators and mechanics about the deteriorating conditions, etc. The TRI emissions rose by about ten-fold to over 2,500,000 pounds/year.
The process safety management collapsed in January of 2010 with major, accidental releases to the air and river and they had a man get killed with a phosgene release. When the US Chemical Safety Board investigated in late 2010, they reported that while the occupational safety and health performance was the best in the DuPont Company, the process safety management had fallen apart and the plant was not even using the DuPont standard procedures. This was a sad commentary about how far things had fallen.
This 19-year case study clearly shows that a highly participative leadership process produces much better results that the top-down management process.
An Online Course Offering
Beginning August 24th, I will be presenting a six-week course on Leadership and Using the Process Enneagram©. The Process Enneagram© was a key leadership tool I used when I was at Belle. I have used this tool successfully around the world with people in all sorts of organizations and businesses in the 25 years since I retired from DuPont. Wherever I have used it in my consulting, safety and total performance has improved.
This Online course is the first in a series to teach about leading and using the Process Enneagram©.
You can’t turn on the news or check your Internet homepage without sensing the depth of the issues that our country is experiencing. Whether it is returning to the workplace amidst COVID-19 rules, political protests, religious non-tolerance, or negative nightly news events – we’re experiencing a wide berth of dramatic events. And each of us has an opinion, a response, a way that we individually see these events and cope with this discord.
It doesn’t have to be that way! Take a timeout!
The pain and suffering is miserable.
Changes are coming fast and furious. Everything seems to be changing all around us. This can cause unsettling feelings and a loss of control. However, in the middle of all this change, one area that can be steady for us is our relationships with each other.
Artificial intelligence and robots, block chains and bitcoins, the opioid epidemic, political strife, and workplace violence, international worries and potential conflicts are some of the challenges facing all of us. There is a critical need for people, in all walks of life, to come together to openly and honestly talk about our challenges, share our thinking and learn together. We do not have to be blindly swept along. We can make decisions and do the things that we need to do to help to make the world a better place.
When I talk about safety. my thinking goes well beyond the traditional safety numbers, training and procedures. It includes ideas about respect and how everyone has agreed to work together. It includes ideas about personal responsibility, integrity and dedication to helping everyone improve. It includes openness, honesty and sharing information abundantly. It includes ideas about the deeper, often hidden patterns of behavior which have a profound impact on the work environment and drive much of the behavior. It includes the fact that the managers and leaders have the largest impact on their organization’s performance. It includes the understanding that managers focus on reliability, stability, predictability and control as they try to maintain the status quo and that leaders focus on the people, change and the future sharing information abundantly, treating people with respect and helping people find meaning in their work. Both good leaders and managers are needed.
For example, the workers on the Deepwater Horizon drilling platform received good recognition for outstanding occupational safety performance (the slips, trips and falls sorts of incidents) just a day or two before the explosion on April 20, 2010, that killed 11 people and injured 17 others. The pressures from top management to get into production led to failures of their process safety management (PSM) systems and processes. Communications were limited because management did not want to hear of more problems; they were driving the production schedule. The fine occupational safety performance masked the PSM deficiencies which are more subtle and invisible to upper managers, unless they are keenly aware of the needs for excellent PSM.
Now we have another example with the mess at Boeing and the 737 Max crashes. Top management was feeling the pressures for market share from Airbus and putting terrific pressures on cost reduction and faster production.
This is quite attainable with authentic, courageous leaders who take a stand that this is the sort of place they want to lead. The knowledge and technology are available and broadly known by lots of people so I want to share my own experiences.
This all began with my determination to work on improving respect, civility and safety. As I built credibility and trust with everyone, people began to make improvements in many other areas. Everything got better.
In 2017, Gallup, Inc. published their “State of the Global Workplace,” looking at the levels of productivity around the world. They were concerned about the decline in productivity and wanted to develop a better picture of the situation. High productivity is a key to having a good quality of life, and this relates to how involved people are in their work. They found that worldwide, only about 15% of the people are highly involved. This varies from country to country with the highest levels of involvement in the USA and Canada at 31%. Those businesses in the top quartile of employee involvement in their global study are 21% more profitable and 17% more productive. They also have 70% fewer safety incidents, 40% fewer quality incidents, 41% lower absenteeism, and 59% lower turnover. The positive impact of employees being highly involved is huge.
Most people in management positions focus on systems and processes like running a payroll or production line. They want reliability, predictability, control, and stability, which are important for much of the business. But when they apply this approach to people, things go downhill. This approach results in 71% of the people globally being unengaged and 19% being actively disengaged. Morale, safety and engagement are a mess. Managers engage in managership, and this will not solve the problem of building higher levels of engagement.
The way in which we think about and work with all the people is a key shift that is needed.Leading thinkers like Eric Hollnagel, Tom McDaniel, Beth Lay, Carl Stent, and Ron Gantt are searching for better, more effective ways of engaging with everyone to build on the good things people are doing.
I feel we are not moving fast enough to get to higher levels of performance. Way too many people are getting hurt and killed. Safety is a part of all we are doing and the whole system needs to be making improvements.
I was given the opportunity to talk about my work on Partner-Centered Leadership and shared information about the Process Enneagram, which is such a powerful tool to help people to come together to solve their complex problems. Partner-Centered Leadership is focused on sharing information, building trust and interdependence, helping everyone see the importance of their work for the success of the whole enterprise and moving into a better future. Everyone at the workshop was seeking ways to actually move into Safety II and make it happen so there was a lot of interest in this work.
A review of the Bureau of Labor Statics summary of fatal occupational injuries for 2011-2017 shows a 1% drop in fatalities from 2016 to 2017 to a total of 5,147 people having lost their lives at work. This is about 9% higher than the 4,693 people killed in 2011. The top three 2017 fatalities categories are roadway accidents totaling 1,299 (up 15% since 2011); slips, trips and falls totaling 887 (up 23% since 2011); and murders and suicides totaling 733 (up by only 2% since 2011).
We need courageous leaders who focus on the people, change and the future. Leaders value sharing information, building trust and interdependence, and helping people to see how their job is important for the success of the whole venture.
Go into your organizations listening to and talking with the people. Share your vision. Build trust and interdependence. Create safe spaces for people to talk with each other, to share and create the future. Everything will change. That is what I experienced at the Belle Plant.
