Safety Isn’t Just Safety Anymore…

February 10, 2023 By Leave a Comment

What every Manager needs to know that OSHA and ISO already do!

It started out in 1970 with OSHA’s regulations to enhance Safety in the Workplace – the first leg of the Safety Stool, a.k.a. as Occupational Safety, exampled by preventing slips, trips and falls, requiring hearing protection, hand and foot protection, and eye-ware.

Then came the second leg of the Safety Stool, Occupational Health, exampled by preventing environmental/respiratory and ergonomic hazards. Then came Process Safety Management (PSM), exampled by what it takes to keep hazardous substances in the pipes, and which became an essential part of workplace safety with the comprehensive issuance of OSHA 1910 – the third leg.

All three legs are important and are critical for Safety professionals, HR professionals, Managers and Supervisors to embrace and for people to understand. Indeed, OSHA requires this attention to keep our people safe (life and limb) within the workplace.

safety in the workplace

Now, with this new decade of Workplace Violence rearing its ugly head, we know that we must add a fourth leg to the Safety Stool. Because attention to this 4th prong needs diligent awareness, it is now becoming paramount that every manager and supervisor be schooled in Situational Awareness:

  • What is happening around you?
  • What is happening between and among people in the workplace?
  • Where are your vulnerabilities?
  • Are you noticing the cultural dysfunction happening in your workplace?
  • Are you able to engage appropriately to find out what’s happening?
  • How do you address these dysfunctions?

The fourth leg of this stool is what is called Psychological or Social Safety. Another way to describe it is the psychological harm that comes with repeated bullying, harassment, incivilities, and dysfunctional behaviors, that leave workers dreading to go to work, or that increase the risk of home-growing an active threat/shooter, or having a suicide or murder in your workplace, let alone the bad press that comes with a highly publicized incident.

If no one steps in to stop bad behaviors when they are happening, they continue and escalate over time. Not paying attention to social risk manifests into psychological harm as the continuum of bad behaviors escalate in the workplace – and ultimately can impact people in harmful ways. Yes, OSHA is keen on this 4th leg of the safety stool, too, and wants to know what your business, company, organization, or team is doing about it. Prevention of Workplace Violence is the operative word.

What is Workplace Violence?

OSHA explains that workplace violence is violence or the threat of violence against workers. It can occur at or outside the workplace and can range from threats and verbal abuse to physical assaults and homicide, one of the leading causes of job-related deaths. However it manifests itself, workplace violence is a growing concern for employers and employees nationwide.

OSHA makes it very clear. Employers are responsible for ensuring that the workplace does NOT become a hostile workplace. (Bullying, harassment, and incivilities contribute to hostile environments). OSHA requires employers to provide a safe workplace for their employees…both physically safe and psychologically safe. This is covered by the General Duty Clause Section 5(a)(1).

Enter the new ISO Standard: ISO 45003 IS THE NEW INTERNATIONAL STANDARD (2021-06) – Occupational Health and Safety Management – Psychological health and safety at work – Guidelines for managing psychosocial risks. This new standard states that Management must be prepared to deal with violence that involves a person (employee, visitor, vendor), etc., losing control, without a weapon. This normally means dealing with psychological safety factors.

It is difficult to predict violent acts, so the Standard expects managers and associates to be vigilant. Report any concerns of erratic behaviors to supervision and HR as soon as possible.

Examples of violent behavior include but are not limited to:

  • Intimidating or bullying others
  • Abusive language
  • Physical assault
  • Threatening behavior
  • Sexual or racial harassment
  • Concealing or using a weapon
  • Anger
  • Tantrums

You get the picture. None of these types of behaviors belong in a workplace, thus the underscoring of new Respectful Workplace policies.

employees need to become stakeholders in their safety

At Nagele, Knowles and Associates, we understand the construct of workplace violence and how to identify it. It starts with knowing your inside culture (culture assessment) to understand where bullying and dysfunctional behavior is happening and how to stop it in its tracks. What is your workplace doing to ensure a Respectful Workplace? It equally starts with a physical security vulnerability assessment to understand where you, your site, your people are most vulnerable to a perpetrator entering your workplace to do harm, and how to deter that from happening.

The 4th leg requires Situational Awareness – that is the tip of the spear when it comes to the prevention of workplace violence…from the inside or from the outside! This holds true in the workplace, and in living our daily lives. Wake up! Be Alert! Observing, expecting, embracing, and requiring a Respectful Workplace is powerful for reducing those harmful dysfunctional behaviors.

Employees must become stakeholders in their own safety and security and develop a survival mindset as well. Vigorous prevention programs, timely interventions, and appropriate responses by organizations and their employees will contribute significantly to a safe, secure, and respectful environment. That’s what we teach; that’s what we do.

Want to know more? Check out our book “Guide to Reducing the Risk of Workplace Violence…the Absolute Essentials” available on Amazon. It has been labeled the “gold standard” – a comprehensive guide to reducing your risk of workplace violence happening in your workplace…from the inside or the outside or give us a call at 716-622-6467.

Filed Under: Safety Excellence, Safety for Business, Safety Leadership Tagged With: , , , , , , , , , , , , , , ,

A Safety Systems View for Organizations

November 10, 2022 By Leave a Comment

Everything happens through the people and all three phases of safety are interconnected.

Note: Many Safety Practitioners go about their safety work task-to-task without considering the broader “systems” in which they work, nor the people that are impacted by their decisions. This newsletter is intended to help lift up safety thinking and actions to a higher level. A systems approach can have a big impact on improving the total safety performance.

In October, I introduced a new figure showing a whole systems view of safety, where occupational safety, occupational health and process safety management are connected and work together through all the people in the organization.

I have thought a lot about this figure and want to share a new figure with you.

the whole safety system

We all live in a world with dynamic systems moving all around us all the time. When we can see the systems around us, we can be much more effective in understanding how things are interacting and deciding what we need to do. We can become much more resilient and sustainable. This is certainly my own experience when working with organizations. In many ways the safety system behaves like a living system where everything is connected and working together.

The traditional approach I see being taken in most safety work is one where the organization is treated as if it were a machine. The belief is that if we take it apart and fix the parts, that it will work better when we put it all back together. The “master mechanic” comes in, fixes the parts, (the employees) and tells it what to do. Improvement is modest at best, and resilience and sustainability are low.

Taking the “living” safety system apart to fix it, kills it.

In thinking about the living safety system, all the people in the organization are involved and partnering to build a better safety future through continuous conversations in a psychologically safe space, at all levels, about how to improve together, think about new ideas, learn, and do things for improvement. All the people in the organization are the center of it all.

Each component of safety is placed around the people. Each safety component has their own particular technology which needs to be done very well. In doing each part as if they are separate does not result in achieving safety excellence. It is in embracing the whole safety system where everyone wins. Together we co-create a culture that is both resilient and sustainable.

You’ll notice that I have introduced a new term I call “Environmental Safety,” which looks at process safety management in a different way. Environmental Safety relates to impacts on people and the air, water and land from wastes, spills, fires, explosions, leaks, sloppy operations, etc. It includes a lot that is already in process safety management PSM When the PSM is done well, the environmental safety is excellent. When the PSM is neglected disasters like the Deep Water Horizon kill people and create huge messes.

The safety system does not exist in isolation. There are a lot of other systems surrounding it that connect directly or indirectly that can be influenced by how well the safety system performs. A highly effective safety system can have a powerful, positive impact on the larger systems in which is functions. A poorly functioning safety system can negatively impact a lot in the larger systems around it, which can then raise concerns, drive regulations, anger the people, the families, the communities and weaken the business in countless ways.

dig deeper to reach a little higher when it comes to business safety

Conclusion

When we use a systems view and see what is going on around us, we are much more able to make effective decisions. Everything moves through the people. In sharing all information, treating people with respect and trust, and giving people the credit for their learning and accomplishments, we create the conditions where energy and creativity are released. We can effectively move in response to changes and become much more sustainable. The people and the business are winners.

Note: I refer to the people in the organization as “people” rather than “employees.” The word “employee” is a legal term that defines the relationship of the person to the organization with things like hours of work and rates of pay. It also carries strong, negative implications about the boss/subordinate relationship. However, referring to people as “people” implies that we are all in this together coming from different perspectives, bringing different gifts, knowledge and skills which are all needed for shared success.

We all work together with respect and build trust.

Please call me at 716-622-6467 or email me at RNKnowles@aol.com if you would like to talk about these ideas. See also RNKnowlesAssociates.com and SafetyExcellenceForBusiness.com.

Filed Under: Safety for Business, Safety Leadership Tagged With: , , , , , , , , , ,

Respect, Trust, Partnering and Safety…Excellence Emerges…and it Matters!

October 10, 2022 By Leave a Comment

Safety and Environmental Performance

When I was the Plant Manager of the DuPont Belle, West Virginia chemical plant, I developed a practice of walking around the Plant 4-5 hours a day, every day for almost 8 years, for the safety of the employees. The plant was a mile long and a third of a mile wide, with about 1,300 people working there.

I needed to engage with everyone to get to know them, their work, and to see what I could do to help them. I did not make decisions as I walked around, since that would weaken the line supervision. I would talk about our mission of being the best we could be with our responsibilities for safety, the environment, the people, the quality of our products and work, our customers, our customer service, our costs, and our community. I would share the news of the day, talking openly about things I knew about the plant, our businesses, and the community.

I would also ask if they had any news to share. I would ask for help in how I could improve my own job. There was a lot of give and take; some days were great and some were very hard. My mantra was, “I don’t have a right to make my living at a place where it was okay for you to get hurt. We also need to make a living so let’s figure this out together.”

we can make a difference for workplace safety by working together

In our conversations, we talked a lot about occupational safety and occupational health. Many good ideas emerged. I would encourage the people to follow-up on their good ideas and support them. We would also talk about process safety management and the importance of keeping the chemicals in the pipes, improving yields, and reducing waste.

I encouraged them to go after leaks and to talk with the engineers about how they could run the processes better. I encouraged the engineers to teach the supervisors and operators about the theory and processes they were running. I encouraged them to learn as much as they could. I would ask about the safety and environmental maintenance work orders and if they were being taken care of promptly. When people asked me questions I couldn’t answer, I told them I did not know the answer, and promised to get back to them with the answer, which I always did.

We had a Central Safety Committee of about 50 people, which met monthly. People from across the organization participated and led the various committees. We integrated all our discussions, so everyone was thinking about their roles in improving occupational safety, health, and process safety. The 4-person safety group, operators, mechanics, supervisors, and engineers were all involved.

While each of the three parts of safety have their own technology, they all overlap in the people doing the work. We saw all aspects of safety and environmental performance as an integrated whole where everyone could make contributions. As the safety and environmental improvements built, this way of working, sharing information, building respect and trust, and helping people to see the importance of their contributions and to find meaning, spread all across the plant.

Treating the People with Respect and Building Trust

In addition to improving our safety and business performance, we emphasized the importance of treating people with respect and telling the truth. I modeled this as I walked around and visited with the people. I apologized for the mistakes I made. I encouraged them to talk together this way as well. I also worked hard to eliminate any bullying or harassment behavior because it is bad for the people and blocks the open flow of information, greatly hindering any improvement efforts. As it became safer for people to speak up and share their ideas and thinking, our total performance significantly improved. Everything happened through the people giving their energy, creativity, and resourcefulness.

The Integrated Whole

Everyone does some of each of these three phases of safety in their jobs. While each of these has different technologies and requirements, they are all in play all the time. For example, an operator moving a container of chemicals needs to be wearing the correct PPE, lifting correctly and being sure that nothing gets spilled. Or a clerical person needs to be seated properly to take care of their back, handling office equipment like scissors carefully, and putting their trash into the proper containers. Or a truck driver needs to use three-point contact when entering and exiting his truck to prevent a fall, have proper cushioning in the truck to support their back and adhere to speeds that are appropriate for the highway conditions.

All dimensions of safety are taking place all the time, as each person does their work. Each person needs to integrate these as appropriate for their particular assignments and tasks. When these are an integrated whole, their jobs are much easier as they think about them together.

Having them as an integrated whole also goes a long way to preventing disasters like the Deep-Water Horizon where the people on the drilling platform received a safety prize for great occupational safety, and then the platform blew up a day or so later because the process safety was falling apart.

The work of the Belle Plant people clearly shows that if we approach safety as an integrated whole, the total performance of the people improves.

approach safety as an integrated whole, the total performance of the people improves

Summary

Trust was built, people opened up, shared their ideas, learned, made decisions about improving their work, and brought occupational safety, health, and process safety management together into an integrate whole. The mood of the entire organization became very positive as things came together. In just four years the people had cut our injury rate by 97% to a Total Recordable Injury Rate of 0.3, reduced our emissions to the air, water, and land by 95%, improved productivity by 45% and increased earnings 300%.

This integrated way of working can happen for your business too. Give me a call at 716-622-6467 for more details. Let’s get started! Please check out our website: Safety Excellence for Business.

Filed Under: Safety for Business, Safety Leadership Tagged With: , , , , , , , , , , ,

Process Safety Management (PSM)…

May 10, 2022 By Leave a Comment

Why Process Safety Management is needed and everyone needs to be Involved!

Week after week I read of explosions and fires at refineries, chemical plants and dust-producing operations like sawmills and grain elevators. There are usually people hurt or killed. Communities are forced to shelter in place or evacuate. Families suffer great loss. There are always estimates of the loss of money and the difficulty of getting back into production.

These are sad situations that are usually avoidable if the managers and engineers would only do their duty to conduct strong process safety management (PSM) work. PSM does require having trained engineers to do the work. It may require money when a defect is found the needs repair. It is often routine and boring work as in inspecting relief valves, for example. It often is narrowly focused on just the specific process without taking the whole system into mind. This is critical work that responsible managers and engineers need to conduct rigorously. It is a necessary discipline. (Process Safety Management came about as OSHA’s response to prevent a disaster like Bhopal).

everyone should be involved in process safety management

When I read the reports of these disasters, there are often long explanations about things. There was one I read about where the fluctuating liquid levels in distillation columns were unstable and causing the operators continuous problems. The instruments were not showing the full nature of the problem of the rising liquid levels which, one day, got so out of control that the distillation column overflowed, releasing a flammable cloud which ignited and killed a lot of people. The incident investigation discussed all sorts of technical problems which were not addressed since they did not look too serious. But they did not include the whole system.

Nowhere was there any discussion mentioned about what the operators were experiencing each day and struggling to control. It was clear that they had a serious problem, but no one asked them about it. Why do the technical people treat the men and women who operate the facilities as if they did not know anything. These people live with the processes! They have a lot to offer!

When I was the Plant Manager of the big DuPont Belle, West Virginia plant, we brought occupational safety, occupational health, and PSM together as a whole safety system effort where each part helped the other parts. We created the conditions where people felt it was okay to talk openly together about the problems and address them. Where they helped each other. Trust was built so people could be able to do their best. The people came together enabling us all to perform much better.

Our Total Recordable Injury rate dropped by 97% to ~0.3 and our total emissions to the environment dropped by 95% in just 3 years. I look at total emissions to the environment as a key PSM metric since there is less waste from poorly running processes and fewer upsets or failures blowing stuff into the air.

Building trust and interdependence among the people is a very important part of management’s work. It is easy to do this using the Cycle of Intelligence, listening and learning together. Rosa Carrillo has written a fine book about the importance of the Relationship Factor entitled “The Relationship Factor in Safety Leadership.” This is easy to do if we just go into our organizations, share information, listen, and learn together. It would have avoided the disaster I mentioned earlier in this newsletter.

Yet most managers do not get out of their offices, talk with the people sharing information, listening, and learning together. Why is this? Rosa’s work and my work clearly show the great benefits to safety and productivity, yet managers shy away from this.

WHY????

In your own organization, what are you doing to open up and share information? What are you doing to open up a safe space where it is okay for people to talk and share? Are you bringing a diverse group of people together to talk and learn?

Each of us can make a positive difference. Will you?

osha process safety management elements

Filed Under: Safety for Business, Safety Leadership Tagged With: , , , , , , , , , ,

Improving Workplace Safety for Your Employees…

September 10, 2021 By Leave a Comment

Many Thousands of People are Being Injured and Killed at Work

Many, many good, safety professionals are working to maintain and improve workplace safety. Yet the number of people losing their lives in our workplaces (in just 4 years) has increased from 4,836 in 2015 to 5,333 in 2019, based on the Bureau of Labor Statistics. From 2015 through 2019 there have been 25,746 people who have lost their lives at work. To put this into an alarming perspective, compare this to the losses in Afghanistan since 2001 (over twenty years) where there have been 3,592 allied forces who have been killed, based on Associated Press.

With all the effort put into improving safety performance in our workplaces, why have we not seen a reduction in the number of people being killed at work? New papers sharing improved ways to ‘improve workplace safety’ are presented at safety conferences by the American Society of Safety Professionals, the American Institute of Chemical Engineers’ Global Congress on Process Safety, and many smaller conferences as well as in publications in a variety of journals. The informational know-how is available!

Each of the specialties of occupational safety, occupational health and process safety management have a huge amount of information that has been developed over the years to improve safety performance. While some progress has been made in reducing the total number of injuries from a rate of 3.0 in 2015 to 2.8 in 2019 (2,814,000 injuries) this seems slow to me.

What is Missing?

The fruits of all this work has to be carried out by the people actually doing the physical work, those close to the actual operating and maintenance processes. We need to help these people, and not just pile more stuff onto them.

wokrplace safety comes down to the frontline people

I have found in all my 60 years in working in research, production and consulting globally that a missing link is not talking with the front-line people and exploring and learning together how to improve the work so that fewer injuries and incidents occur. None of us have all the answers. We need each other. (Talking down to people doesn’t work; talking to people (one-way) doesn’t work—the key is in talking with our people!)

Here is a Simple Solution…

When I was the Plant Manager at the 1,300 person, DuPont Belle, WV Chemical Plant I changed this. In my leading process, I spent 4-5 hours a day for 7+years walking around in the Plant, being respectful, sharing information, listening, asking how I could help the people, asking them for their help, learning together to improve things and building trust and interdependence. I talked with everyone. My mantra was “I do not have a right to make my living at a place where it is okay for you to get hurt, and we have to make a living, so let’s figure this out together.”

Our injury rate dropped by about 97% in three years, emissions to the environment dropped by about 96% in 4 years, productivity rose about 45% and earnings rose about 300%. Safety is connected to everything so as we made safety improvements everything else improved. In this approach which I call “Partner-Centered Leadership”, all parts of our safety work came together as shown here.

partner centered leadership for workplace safety

Each of occupational safety, health and process safety have their unique knowledge and management disciplines. When they are brought together, in the region of overlap in the center of this Venn Diagram, this is where the people and the leading process described above come together. In addition to talking with everyone about all the dimensions of our safety work as I walked around, there was one place where this all came together and was clear to everyone. Our monthly Central Safety Meetings were open, and all aspects of our safety work were discussed openly with everyone. All questions and concerns were welcome, and fixed. I strongly urged our supervisors to talk with their people and the engineers to sit with the operators to teach them the elements of process safety.

This is Simple.

Go into your workplaces, respectfully talk with the people, listen, share, ask them where you can be of more help, help them to follow up on their ideas and concerns, solve problems, build trust, and have everyone go home healthy and in one piece. Engagement!

You can do this!

To learn more about this approach see our web sites:
RNKnowlesAssociates.com and SafetyExcellenceForBusiness.com or give us a call at 716-622-6467.

Filed Under: Safety for Business, Safety Leadership, Safety Leadership Process, Safety Partnership Tagged With: , , , , , , , ,

Bringing Safety People Together…It’s all in the Venn!

January 11, 2021 By Leave a Comment

I want to share some experiences I’ve learned about the importance of sharing information and building trust – especially as it applies to the various safety aspects of our workplaces.

We surely had our hands full in 2020 with all the COVID-19 issues. While the new vaccines will help, change will always be with us. Each of you can make a positive difference for the people in your organizations by sharing information about what is going on, building respect and trust and listening carefully, so you really understand the issues and concerns.

I have noticed that those working on occupational safety and occupational health do not interact much with the people working on process safety management (PSM), and vice-versa. For example, at the ASSP meetings, I rarely hear any one talking about PSM and at the AIChE Process Safety meetings, I don’t hear much about occupational safety and/or occupational health. It is as if these are different stove pipes. But each of these are areas where people are deeply involved in the total safety performance of the organization. I have found that when everyone is talking together about the total safety, synergy emerges and all areas benefit.

When I was the Plant Manager of a big chemical plant, the people working in these three areas were engaged in conversations and contributed to improvements across the board. This Venn Diagram illustrates how we brought them together while maintaining their unique contributions.

the importance of sharing information and building trust

Each safety area was managed separately, using their own operating discipline. Where the three areas came together, we talked about what was happening and looked for input from each other. This significantly raised the total safety and environmental performance of the site. PSM also has a big impact on the environmental performance when spills, accidental chronic emissions, release incidents, improved yields and fires and explosions are eliminated; and a lot less is emitted to the environment.

The area of overlap of the three safety disciplines (at the center of the Venn diagram) is where we engaged in Partner-Centered Leadership:

  • Sharing all information
  • Building trust.
  • Listening to each other’s problems and opportunities.
  • Learning and finding better ways to do the work together.

For example, we talked about the three disciplines in our site Central Safety Meetings, keeping careful track of our safety workorder backlogs, meeting our safety equipment inspection schedules and talking about incidents and injuries that had happened, and what we could all learn from them. The engineers went into the various production areas and sat with the operators to learn what the operators were experiencing as they ran the processes, and the engineers taught the operators the engineering technology supporting their work, helping them to understand what was happening in the manufacturing operations. The supervisors, engineers, operators and maintenance people talked together as safety and work procedures were developed. The gap between work-as imagined and work-as-done virtually disappeared. As trust and the open dialogue improved, our safety and environmental performance really improved.

In just three years, the Total Recordable Injury Rate dropped by about 97% to a rate of about 0.3, and the people sustained this for 17 years. PSM improved with much lower levels of releases and upsets. The emissions to the environment (accidental and permitted) went down about 95% in four years. When the PSM was run as a separate stove pipe from the occupational safety and occupational health stove pipes, the Plant’s performance did not come anywhere close to these low levels. This is significant!

The improvements we made in how we worked together in safety spread into all the other parts of our work in running the big (1,300 people) chemical plant. The more we shared information, treated each other with respect and listened to each other, the more the total performance improved. For example, productivity rose by about 45% and earnings rose about 300%.

Learning to work more effectively, through our safety work, spread to the whole organization. Each of you reading this newsletter can make a big difference as you engage with the people in your organizations, sharing information, building respect and trust. The impact of your work will spread.

Want to know more? Contact me at 716-622-6467. Or, Order my book, “Partnering for Safety and Business Excellence” on Amazon.

 

Note: Venn is a diagram that shows all possible logical relations between a finite collection of different sets. Take a look at what sits right in the middle!

Filed Under: Safety for Business, Safety Leadership, Safety Partnership Tagged With: , , , , , , , , , , ,

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