June is National Safety Month

Safety Challenges are Still With Us!

national safety monthIn times like this, when the business and production activities are ramping up, there is a real danger that safety problems will show up. Any time the level of activity changes, up or down, is a time of danger.

Talk with the people about these issues as well. Every day have tool box or pre-start meetings to talk about the challenges for the day. Ask the people what their biggest hazards are for the day and what they are doing to prepare for them and to protect themselves and the processes. At the end of the day, have another safety conversation and reflect on the day and whether the things that they talked about at the start really helped. Talk about the surprise for the day and how they overcame these challenges.

Keep the safety dialogue going. One of the best ways to show that you really care about the people is to work hard on the safety front. Go into the workplaces, listen, talk together, and build collaboration, helping everyone to work towards a healthy, safe and profitable business.

Safety II – What it is…and Why we Need it!

In my last Safety newsletter, I wrote about the need to significantly improve our safety performance.

safety excellence in business leadershipI 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.

A big step was taken towards this goal in a Safety II in Practice Workshop in Saint Petersburg, Florida, on February 24-27, 2019. This excellent gathering was organized and brought together by Tom McDaniel, a widely experienced, practical safety leader. One speaker was Eric Hollnagel who has written several books about Safety II. He summarizes Safety II as “the ability to succeed under varying conditions, so that the number of intended and acceptable outcomes is as high as possible. The Safety II perspective looks at how work goes well and tries to understand how that happens in order to ensure that it will happen again.” The shift from Safety I, where we look at what went wrong, to Safety II where we look at what is going right and learn from it is critical for our work to attain higher levels of performance.

Tom McDaniel spoke of our obligation to present the closest interpretation of the truth in our organizations enabling the people to be given enough information to make the best possible decisions. We need to engage the people to help to improve our total performance including safety and reducing the number of incidents and injuries. We need to understand and build upon the things that people are doing right. He shared many practical examples to illustrate this.

Ron Gantt spoke about the need to widen our gaze to see the complex interactions of everyday work so we can see opportunities for improvement and facilitation rather only violations. He talked about the importance of going into our organizations, being with the people and seeing how they really do their work and the challenges they face every day as they get the jobs done. It is important to close the gap between work-as-imagined and work-as-done.

Our Safety I habits are strong and it is not easy to move into a Safety II approach and sustain it. Safety I and Safety II are not in opposition to each other. Rather we need to take the best of the basic rules, procedures and skills of Safety I, and build the positive approach of Safety II into our way of working with the people at all levels in the organization so that everyone can be the best they can be.

Richard N. Knowles speaking at the safety conferenceI 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.

Tom McDaniel was gracious in commenting:

Dick Knowles has the most effective process for understanding and measuring leadership and its advancement. His knowledge on this subject is outstanding. He brings clarity to what many are already doing in an ad hoc method but by seeing this relationship distinction, it can only help you and your organization move further along. I know he has written a couple of books on this. He has helped many organizations succeed.

This Workshop was an exciting step into a brighter future for the people in our organizations. Many thanks to Tom McDaniel for having organized this workshop and bringing everyone together to share and learn.

It is all about “YOU”

It is a new year. Businesses have compiled their 2018 safety statistics. They are looking at economics and at people. Who was hurt during this past year? What have we put in place so that those injuries won’t happen again? What are we talking about together for betterment? How did our systems contribute to our successes or to the injurie/s? What was the presence and the strength of Leadership support like around those people who were injured? Where are we most vulnerable safety-wise? How can we lead more effectively? How can we have an even safer workplace in this new year, 2019? How can we help employees to become more aware, more safety vigilant? And thus more able to return to their families at the end of the shift whole – with arms, legs, toes, fingers, eyes, ears – all intact. (Leaders, are you asking these questions?)

I don’t believe anyone wakes up in the morning and then upon entering the workplace plans on getting hurt that day. Nope. It doesn’t work that way. Rather, we go into work, we start our work, and our focus tends to wander from safety – inattentiveness – hurrying – trying to do two things at once – perhaps even emotionally upset at times. The result is that slips, falls, pinches, pinnings, caught between, run over, cuts, scrapes, and near-misses or worse scenarios come about. Somehow we drop the ball on being able integrate safety into the whole task from the initial safety reminders to the safety wrap-up at the end of the day. Even in-your-face safety signage doesn’t save the day.

It doesn’t have to be that way. Nope. Safety starts when YOU—the individual person takes a stand that YOU will work safe…all day. YOU will ask yourself where the biggest risks are and how you must prepare for them. YOU will watch out (as well), for your buddy and the newbie. YOU are an adult. YOU don’t want to have to wear a brace or a cast or bandage because of the pain and the inconvenience it’ll cause you. YOU don’t want to have to miss work or become a statistic. YOU will look out for booby-traps and surprises. YOU will be attentive to what is happening around you and with your specific task. YOU will be your own poster child for doing your work safely…because YOU want to…because it is the right thing to do, because YOU can think for yourself. YOU don’t need to have a safety prize for a reward, either. YOU decide to be safe…everyday, every moment, every task, constantly building on the good things you know and strengths you have. YOU make the decision!

Why am I beating this drum today for this newsletter? Because it is a clear aspect of Safety and Leadership. Until YOU can take a stand…a genuine stand…on YOUR own Safety, your head won’t be or stay in the game. And Leaders, Supervisors, Managers, CEO’s, you need to take your stand, too. Your stake has to be clearly and visibly in the ground. Your people need to know that you’ve taken your stance on safety and expect the same of them.

What does “taking a stand mean?” It means that not only will you publicly share that you recognize that YOU believe that working safely is important and something you must do, but you are, in addition, willing to ask all those you work with, to kindly hold you accountable to that stand. Will you do that? What’s your stand?

That’s the difference that makes the difference!

Part 1: The Background on the Cruise Line International Association Conference

On December 16-18, 2015, I was able to attend the Cruise Line International Association Safety Conference in Miami. The focus was on improving the safety culture and Bridge Resource Management. This is a very interesting business for me to learn about. I was there to give some perspective from the chemical industry.

This cruise line industry is doing a lot to keep improving their safety performance. Their safety challenges range from slips, trips and falls all the way to navigation, building effective teams on the bridge and crew communications challenges. Ken Koves from the Institute of Nuclear Power Operations spoke about safety culture from their perspective. The level of regulation in that industry is quite impressive. There is just no question about doing things safely, yet they still have their challenges.

I spoke about moving towards a stronger safety culture by sharing more information, building trust and helping people to see the importance of their work to the success of the whole effort. I showed the 35 attendees a slide about the layers of the safety process effort, which they found quite interesting. I also gave them some cards with tips that the officers at different levels could use to help them when they go out to talk with their people. These were seen as quite helpful as well.

The second day focused on training, bridge resource management and simulation so that the captains and their bridge officers could develop stronger skills relating to navigation, ship piloting and management skills.

There is some very sophisticated work being done with large simulators being used by several companies. There are also several institutes providing skills, refresher training and qualification for the officers. Their training loads are very heavy.

Two test pilots from Boeing spoke about their training and the use of simulators. Their simulators are so advanced that, after a month of simulator training, a person could fly an airplane even though they never had seen it before. The basic ideas about the way simulators help them are quite alike even though the differences between a single seat jet fighter and a cruise ship are huge.


Part 2 – Integrating this Learning into all Safety Leadership

There is a big need to be sure the managers of chemical plants are qualified so that their employees and neighboring communities do not suffer the consequences of chemical releases and spills. Many manufacturing businesses that do hazardous work, aside from chemical manufacturing, should heed this thinking too.

As I was listening to these talks, I got to thinking about my chemical industry experiences. When I was a DuPont Plant Manager 20 years ago, we were very strong in operating discipline and safety. Managers were carefully selected and a lot of attention was paid to doing safety and everything else right. Training and integrating safety into every task, every day, was paramount.

Over the years, since I retired in 1996, a lot has changed, with the terrific pressure on cost control and efficiency. The safety standards fell terribly and accidents occurred like the four LaPorte, Texas deaths that DuPont had in October, 2014. In reading the reports of that accident it was sad to see that standards had slipped so far that even their company fire truck broke down on the way to respond to the incident.

This isn’t just a DuPont problem. Many companies are being broken up and purchased by finance and fund managers who know nothing about manufacturing and the high standards that need to be met. Just look at the First Chemical Company spill in West Virginia, when their poorly maintained storage tanks failed, spilling chemicals into the Elk River near Charleston shutting down the city water system for weeks. The people who owned this facility had no idea about their safety responsibilities. Their tanks were leaking for some time, yet the owners ignored them; the size of the leaks increased over a considerable period of time, then the dikes finally failed.

I am beginning to think that the people who manage facilities using highly hazardous materials, like those on the TSCA list, should have some sort of licensing requirements to certify that they are qualified and that their companies know how to fulfill their safety responsibilities. Ship Masters have licenses and certifications. Nuclear plant people are certified. My barber has to have a license. Professional Engineers must be licensed.

While this may sound like just more red tape, I think it is time to open the conversation about this. Plants that handle chemicals like chlorine are hard to run, can fall into a backwater and not receive the attention and support they need – yet a big chlorine spill would be a disaster.

There are lots of questions related to getting this going, but we, as a society, need to address it. What are your thoughts? What areas in your specific business, (chemical or not), are such that being certain that your managers and owners know what they’re doing and have the required knowledge and demonstrated operating discipline, are paramount? Where do you need to put some marked attention in 2016?

Safety Never Takes A Holiday…Not in Hunting Season Either!

Safety Never Takes A Holiday…Not in Hunting Season Either!

In many places, the hunting season is underway or just beginning. This is always a time of change and hazard. Some years when I was a plant manager, we would have one or two serious hunting-related, off-job injuries – like falling from a tree stand or tripping over something and breaking a leg. There is a lot of change as people go into the woods and fields looking for game. Many have not done this for a while. Others may not be fully prepared for a sharp change in the weather where a heavy rain could come in or the temperatures drop below freezing and hypothermia becomes a worry. It is often dark and visibility is poor. I have read of hunters getting killed with their own weapon when they have tripped and accidentally shot themselves. Don’t load your gun until you are ready to use it.

There’s a certain excitement that pervades hunting season, especially with newbies to the sport, so hunting safety cautions and reminders are good to reinforce. Be especially careful and safety-instructive when you have hunting novices with you!

Safety never takes a holiday – not in hunting season either!

Checklists Really Can Save Lives!

BrochuresI have been talking about checklists in my previous newsletters and they can be useful as people go out hunting.

Consider this mental checklist:

  • What sorts of special hazards do you face when you go out into nature and experience the thrill of the season?
  • Are you alone?
  • Do you have a flashlight if necessary?
  • A compass?
  • A cell phone?
  • Do people know where you will be and when to expect you to return home again?
  • Is your equipment really ready to do what you need?
  • Are your weapons in excellent working order?

Too many questions????? My wife’s father died while he was doing what he loved – deer-hunting; but his heart was not strong enough for the exertion required in that terrain.

What about you? Are you healthy enough for the hunt? Do you have your emergency meds with you? Could you get help if you needed it?

Another change for many of you will be related to Thanksgiving and the travel to be with family. Here again checklists would be useful.

Consider this mental checklist:

  • Is the car in good condition and serviced properly?
  • For those up north, do you have a few blankets and emergency rations in case you get into a surprise storm?
  • Are your maps and plans well thought out for the routes and times of travel?
  • Are your tires in good shape?
  • Do you have your ice scraper?
  • Is your cell phone charged?

For the hunters and seasoned travelers, you probably have a pretty good fix on these things. However, in the hurry to get into the field and woods or get moving on your trip when people are anxious and a little uptight, it is easy to miss a critical thing. How many times in the past have you started out and remembered you left something important behind? A simple checklist, written or mental, could make a big, positive difference in your adventures! Remember, safety never takes a holiday!


Checklists in the Workplace

I recently read of a fatal accident where a man was killed while working on a lathe. It was properly shielded and okay for the normal conditions, but the unexpected happened. The part he was working on exploded apart under the high rotating speed when he engaged the cutter. The parts from the exploding piece went right through the shield and gave him terrible, fatal wounds.

As you get ready to start your jobs – talking together about being fully prepared – it is important to imagine the unimaginable. What unlikely thing can happen that can get one of you killed if things go in unexpected ways? For many of these unexpected events there are no safety procedures developed. They lurk just outside of the normal path of events for which we have plenty of rules.

We often discover these lurking tragedies by talking together and thinking out loud about things. This requires a culture where it is expected that you will talk together, listen carefully to what you are hearing, asking questions and being open to something new. Sometimes when two seemingly unrelated ideas come together new insights emerge that could reveal a potentially serious accident. Often when we are listening to comics, two seemingly unrelated ideas are put together can be really funny. Conversely, thinking of two, seemingly unrelated things or events could save a life.

Thinking about the unexpected can be a powerful thing. (Put that on your mental checklist!)


Backfilling: The Hazard of Temporary Workers

Another thing that can happen around hunting season and the holidays is the need to hire temporary people to backfill for those who are out. These people need extra care and attention, but things are often so busy that it is hard to give it to them. These people just don’t know the hazards.

I heard a story about a high school aged fellow who came into a box making plant as a temporary employee and was assigned to a box-making machine. He was told to push the red button and the cardboard would be fed into the machine, scored, cut, folded and glued, then the finished box would be ejected from the machine. They also told him that now and then the machine would jam so he would have to quickly crawl into it to pull the cardboard out. Over the next few weeks, he successfully pull out some jammed boxes, but one day he did not move quickly enough and got pinned in the machine. Fortunately his heavy sweater got caught in the machine, jammed it and saved his life. He did get a long cut in his leg. He was stuck in the machine for about 30 minutes before someone discovered him and got him out and to medical help.

This is a pretty extreme example, but it illustrates the point. Look out for the temporary employees and help them. They are people too!

Checklists Really Can Save Lives!

BrochuresIn many of my newsletters, I have talked about the importance of sharing information abundantly, building relationships of trust and interdependence, and helping people to see the importance of their own work in building the success of the whole organization.

I have also talked about the importance of each person being centered, having the best available information, and help at the specific time when they have to make a decision and do their work. When they turn that wrench, press a switch, or open a valve, they need to be fully present to their work and have teammates who will help them to think through the immediate issues so that the likelihood of an injury, incident or fatality is very low.

This is really important:

In recently reading Atul Gawande’s book, “The CheckList Manifesto” (2009), which is a NY Times Best Seller, it occurred to me that there was something here that could be very useful for the people doing the work in our plants and factories.

Dr. Gawande is a fine surgeon who has a deep interest in improving the success of surgeries by eliminating the things that can easily go wrong and result in a serious injury or death to the patient. These wonderfully trained surgeons are working in a highly complex environment where things can be missed and mistakes made. In working in all sorts of operating rooms across the world, they:

  1. found that simple steps, like knowing each other on the operating team, the timing of giving the antibiotics and anesthesia or having a backup plan, were missed about 25% of the time and
  2. that by using checklists, mistakes dropped around 35% and deaths fell 47%.

These checklists are quick, simple tools to support highly-trained professionals and produce very significant improvements in safety at essentially no additional costs or time required. (Nothing complicated!)

When he looked at how airplane pilots used checklists in their highly complex situations, he found that they were used to avoid missing critical steps in the preparation of their aircraft before takeoff to ensure the safety of these highly trained professionals crews and passengers in both military aviation and the airline industry.


How Can the Use of Checklists Help Your Safety Performance?

In our plants and factories, it is critical that those doing the work are fully present mentally, physically and emotionally so that the safety of themselves, their work partners and others is maximized. Two places where simple checklists could be quite helpful are in shift start meetings and doing a “Take-Two” just before a maintenance job, a repair job or in trouble-shooting. These would be simple, carefully crafted, focused checklists that could be reviewed and used in a couple of minutes to make sure that everyone on that job is fully present and ready to do the work. These are to support and remind skilled people of several critical factors that could make the difference between a smooth, skillful, successful meeting or job and a disaster if something was missed in the hurry to get into the work.

These checklists are not the usual ones we see being used to be sure the equipment is checked out, rather they are checklists to be used to be sure that people have cleared their minds and are fully present mentally, emotionally and physically ready to do the work safely and well.

Just before a shift start meeting or at the beginning of a maintenance or repair job, the leader could quickly skim the checklist to remind him/her of key issues facing the people on the shift and remember to talk about them together. As they talk together, they can check to see if everyone is physically, emotionally and mentally ready to work and develop a better understanding of the day’s challenges and tasks. They can ensure that the right equipment and PPE are available and will be used, that the right people will be involved, and that they have a backup plan if something goes wrong. They will see if they need to ask for help from other groups for the bigger or specialized tasks. There will also be reminders about not taking short cuts and stopping the job if it can’t be done safely.

The checklists can easily incorporate the sharing of information, building trust and interdependence and helping people to see the importance of their work while also focusing on the particulars of the immediate work. These would serve as tools to support the highly skilled people doing the work.

Since so many of our injuries and fatalities occur in driving accidents, a simple checklist could be used to help drivers to remember 3-4 key driving principles when they step into their vehicles before starting the equipment.

These checklists can be a very simple, easy way to significantly reduce incidents, injuries and fatalities.

Leading Safety…Working with People because People are the Key!

Safety 2015,” the Annual ASSE Professional Development Conference and Exposition, was held in Dallas, Texas, in early June. It was a terrific conference and gathering of about 4,000 safety professionals. There was a lot of networking, excellent keynote talks, a vast array of all kinds of safety equipment, and lots of papers in concurrent sessions. About 100 people came to hear me talk about achieving sustainable and excellent levels of performance. Total Recordable Injury Rate was <0.4 for 16 years when we approached the organization as a complex adaptive system (CAS).

There was a lot of interest in this based on the attention of the audience, the quality of the questions and the excellent feedback I received at the end. This was the only paper addressing the complex adaptive systems approach to achieving safety excellence at this conference. Based on my experience, this is a much easier and more effective way to lead safety. The Safety Leadership Process©, the correct tool for use in CAS, requires the leaders to get clear and focused in their safety thinking and message, then go into their organizations listening, talking, abundantly sharing information with the people about how to get better and then helping the people to implement their improvement ideas.

While the conference and exposition presented lots of good papers and displayed a huge array of safety equipment, I got the feeling that a lot of people think that they are disempowered for making safety improvements. Many lament, if only management would listen to the safety professionals, or if we added more focused safety people, or if we could purchase more of the fancy new equipment like that on display, that maybe then our safety would get better. Is this not more of the same way we have been managing safety for years?

I think that more technical papers, more traditional training activities, and new safety equipment will only get the organization to the level of safety compliance – it does not get organizations to the level of safety excellence. I have tried this technical-based approach over the last 50 years without achieving safety excellence. And why? Because people are the key!

But, when I shifted to using the Safety Leadership Process©, described above, the shift in attitude, the willingness to improve performance, and the energy and excitement of the people, enabled the organization to reach and sustain the higher level safety excellence.

Those in leadership positions and at the top of the organization have the responsibility to engage with the people – setting the conditions where excellence can be achieved. This only requires a commitment to get clear on the safety message, go into the work places and engage with the people exploring new and better ways to having every one go home without having been injured at work. With courage, care, concern, and commitment, we can all reach and sustain the level of safety excellence!

Visualizing the Future to Avoid Fatalities

Visualize the Future to Avoid FatalitiesIn my reading, studying and talking with many people, I have found that over half of the fatal accidents are often unanticipated and missed using our traditional approaches to accident prevention. The Heinrich Accident Triangle is very useful as we look at unsafe acts at the base of the triangle. Lots of slips, trips and falls are avoided as we do this.

But, many potential, fatal accidents don’t show up in this work. Only very few of the unsafe acts at the base of the triangle ever lead to a fatality. Why does a man fall from a cell phone tower when he has his fall protection harness on properly? Why does a man rush down the ramp to quickly fix something at the end of his shift where big paper rolls are stored prior to loading, when he knows the dangers of getting caught between the rolls and getting killed? Why does a man jump onto a large baking oven conveyor belt in a hurry to enter the oven before it is cool enough to do some maintenance and gets killed? These sorts of impulsive, tragic actions aren’t picked up in our normal safety audits.

Yet many of the reports of fatal accidents indicate that the conditions and impulsive behavior surrounding these accidents were obvious in hindsight. As people think about the fatality, they often see that, while the obvious conditions and impulsive tendencies were there, they were not in people’s everyday conscious thinking.

Often, the causal details are a mystery like in the situation with some of the fatal falls from cell towers and the workers have their fall protection gear all on but somehow they didn’t have it hooked up for a fatal moment. Or the man caught between the big rolls of paper or the guy who got cooked.

One possible approach to eliminating these sorts of fatalities is built on the belief that the people closest to the actual work are in the best position to see the obvious if they open their minds. Suppose that, once a month, the various work groups take 30 minutes to think about their work with the focus on identifying the conditions and work practices possibly leading to unlikely events and potential fatalities. Think about what work the people actually have to do to get their job done. They would open their minds to unlikely possibilities and see if there is something coming out of this that would alert them to a potential fatality. Including a few people from another work group with fresh sets of eyes would be helpful.

Here are some questions to consider:

  • Are there high pressures to get the work done quickly?
  • Do people just jump in impulsively?
  • Do the people talk about both safety and production and the need to do both well?
  • Is there information that needs to be shared that would help to prevent a potential fatality?
  • In your safety culture, is it okay to stop the job to fix a safety issue?
  • Are procedures gradually being changed that might weaken the protection?
  • Do people really trust and help each other?
  • Can you reach out to an impulsive person and hold him/her back?
  • Those closest to the work know their work and their work-mates better than anyone else and can explore the unlikely possibilities. Supervisors and managers should also be included and support this effort.

Once they have discovered a potential fatality situation, they could put together a team to focus on it and develop ways to eliminate or modify the conditions, behaviors and procedures that could lead to a potential fatality.

This important work should be shared with all the other people in the organization so that everyone can learn and improve. Keeping track of these disaster prevention sessions could become a leading indicator of the safety culture.

The Gift of Discretionary Energy

We can reach safety excellence only if we all pull together, giving our best. This takes extra energy over and beyond the energy we need to put into our job to keep from getting fired.

safety leadership tips Talking together is one of the most important things we can do to help to improve the safety in our workplaces. Letting people know that you care about them and respect them. But too many times I have seen supervisors and managers talking down to their employees ordering them to do this or that.

This is energy that we can give or withhold. This is energy that people will freely give if they are feeling valued and want to help everyone go home in one piece.

We can help people to feel really valued when we take interest in them, help them and ask them to help each other for the good of the whole organization. Being open and honest is a big part of this. Being consistent in working with them this way shows we are serious about them and want them to be a part of the team. Being clear, consistent and fair in holding everyone up to meeting the safety standards, not tolerating bully’s, and telling the truth are keys to this as well.

This is the way that most of us want to be treated so let’s do it for everyone!

For a Safe Workplace Look at What You See

We are constantly looking for indications relating to the strength and health of the safety climate in our facilities.

In January I talked about leading indicators I have found useful for occupational safety, health and process safety management. Another quick way to assess the safety climate relates to looking for the use of improper, makeshift tools. These can often be seen as we move through our facilities.

how to spot safety issues in businessAt a recent safety conference I learned about a way to quickly assess whether a manufacturing site was cutting corners and trying to get by on less than the best. The person speaking, Ewan Alexander of BHP Billiton, said that he looked for improvised tools being used.

An example is a wrench with a piece of pipe shoved over the handle to make the handle longer and thus be able to turn a bolt that should be turned by a larger wrench properly designed for the job. Pounding the handle of a wrench to loosen a bolt is another example of improper tool use.

Improperly Using PPE, like using a small respirator when full-face protection is required, is an example of cutting corners. Using dirty, partly opaque face-shields is another example. Using the wrong choice of gloves is another indication of cutting corners and poor decision-making.

The presence or absence of these problems is something we can observe if we pay attention.

When we are awake and making observations, we can quickly see how we are doing and take actions to improve things.

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