M.Guneri / HS Mang. 1

301 Coal Miners died in an occupational accident in

Soma in 2014.

Health and Safety Management System to Prevent Workplace Accidents

Melih Güneri

2

Health and Safety Management System

M.Guneri / HS Mang.

Phase 1 - Policy

• Setting Policy• Identying Target• Setting KPIs• Master Plan• Creating a Team

Phase 2 - Data Collection

• Unsafe Act, Unsafe Condition• Accidents and Near Misses• Health Checks, Indoor

Environmental Conditions Measurements

Phase 3 - Risk Assessment

• Risk Assessment Flow• Controls, Preventive Actions• Improvements• Behaviour Change

Programmes / Indirect Trainings

Phase 4 - Audit & Revision

• System Audits• KPIs Evaluation• Revision on Master Plan

Agenda

4

Phase 1 – Policy

Setting Policy

M.Guneri / HS Mang.

Different industrial sectors

can add extra commitments Less Automated Industries

• Provide best practise of manual handling.

Chemical Industries • Provide the best working

environmental condition possible

Must be committed to all employees to prevent accidents and occupational illness

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Phase 1 – Policy

• Key Performance Indicator (KPI)

• Key Activity Indicator (KAI)

M.Guneri / HS Mang.

Policy

KPIs Number of Accidents

Number of Near Misses

Number of Occupational

Illness Number of

Medical Syptoms

Percentage of Absenteeism

Number of Unsafe

ConditionNumber of Unsafe Acts

Number of Training

KAIs

Risk Analylsis

Ergonomic Analysis

Medical Health Check

Unsafe Acts Observation

System

Unsafe Condition

Observation System

Trainings

Audits

Identifying Target

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Phase 1 – Policy

M.Guneri / HS Mang.

Team KPI 2014 Realization 2014 Target 2015 Target 2016 Target 2017 Target 2018 Target 2019 Target 2020 Target

Number of Accidents

Number of Near Misses

Number of

Occupational Illness

Number of Medical Syptoms

Percentage of Absenteeism

Number of

Unsafe Condition

Number of Unsafe Acts

Number of Training

Setting KPIs

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Phase 1 – Policy

M.Guneri / HS Mang.

ROUTE STEPSPhase I Phase II

2014 2015 2016 2017 2018 2019 2020 2021

1 Assess Current Situation

2 Restore Basic Conditions

3 Accident & Near Miss Analysiss

4 Risk Analysis

5 Set up Data Collection System

6 Proactive Work Place Improvement

7 Innovative Improvements

8 Eradicate a specific risk

9 Set Up Advanced Emergency Management System

Master Plan

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Phase 1 – Policy

M.Guneri / HS Mang.

An Exapmle Of Team

• HS Resposible / Team leader• Workplace Doctor / Team Member• HS Support Employees / Team Member • Production Responsible / Team Member• Maintenance Responsible / Team Member • Production Worker / Team Member

  Team

Tasks HS Resposible

Workplace Doctor

HS Support Employees

Production Responsible

Maintenance Responsible

Prod. Worker

Strategy & Targets Responsible Assistant     Method Responsible Assistant Assistant Assistant  

Master Plan Responsible Assistant  

Trainings Assistant Assistant   Responsible

Accident & Near miss Responsible Assistant Assistant Assistant Assistant Assistant

Occupational Illness & Medical Syptoms

Assistant Responsible Assistant

Unsafe Acts Assistant Assistant Responsible Assistant

Unsafe Conditations Assistant Assistant   Responsible Assistant

Creating a Team

Phase 2 – Data Collection

M.Guneri / HS Mang. 9

Unsafe Conditions

Unsafe Acts

Unsafe Acts Observation and Reporting

• Employees observe themselves and report

Unsafe Condition Reporting

• Employees reports unsafe conditions by visibly marking

Rewarding system is the key !

• Advantage Disadvantage:

• Advantage : Disadvantage:

• Advantage : Disadvantage:

• Advantage Disadvantage:

Unsafe Act, Unsafe Condition

• Employees reports unsafe conditions by software application.

• Selected group observe and report

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Phase 2 – Data Collection

M.Guneri / HS Mang.

Accidents Reporting

• Area responsible reports

Near miss Reporting

• Area responsible reports

Accidents and Near Misses

• Employee reports his own near miss.

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Phase 2 – Data Collection

M.Guneri / HS Mang.

Health Checks, Indoor Environmental Conditions Measurements

• Health check results comparison present and previous year.

• Noise• Dust• Vibration• Lighting • Chemical Vapours• Thermal Comfort• Ventilation• Micro-organism on

equipments

• Datas for health checks

Results

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Phase 3 – Risk Assessment

M.Guneri / HS Mang.

1. Collected Datas

3. Take Preventive Actions, Controls,

Improvements

2.Evaluate The Risks

3.Train the employees

Risk Assessment Flow

4.Evaulate the effectiveness of

actions

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Phase 3 – Risk Assessment

M.Guneri / HS Mang.

What to control ?

• Electronic safety systems or manuel safety sytems

• Emergency control systems

• Electricity system

• Lifting eqipments, presure pots

• Other Equipment

Controls, Preventive Actions

Output of risk analysis for controlOutput of risk analysis for

Preventive Actions

To abolish to use unsafe knives

Evaluation on Counter Measure Ladder

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Phase 3 – Risk Assessment

M.Guneri / HS Mang.

Improvements

Before After

Do improvements and display on boards !

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Phase 3 – Risk Assessment

M.Guneri / HS Mang.

Behaviour Change Programmes / Indirect Training

Super Hero / Safety Man Character

HS slogan contest among employees

Activities

• Safety Man Characters

• HS slogan contest

• Role Playing

Games

• HS Week Celebrations

• ‘0’ Accident Theme Social Activities

Objectives• To support the change of habits and

operational blindness

All designed by Lütfü Altan

16M.Guneri / HS Mang.

‘0’ Accident Theme Social Activities

Phase 3 – Risk Assessment

Role playing HS games

HS Week Celebrations

Behaviour Change Programmes / Indirect Training

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Phase 4 - Audit & Revision

M.Guneri / HS Mang.

System Audits

What to audit ?

• KPIs

• Reporting system (Data Collection)

• Controls and preventive actions (Risk Assessment)

• Programmes, campaings

• Follow up system

Internal Audit External Audit

What to audit ?

• Total system

Outputs

What can do better ?Correct the failures and

Improve the system

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Phase 4 - Audit & Revision

M.Guneri / HS Mang.

KPIs EvaluationTeam KPI 2014

Realization2014 Target 2015 Target

Number of Accidents 2 0

Number of Near Misses 10 5

Number of Occupational Illness 0 0

Number of Medical Syptoms 6 15

Percentage of Absenteeism % 0.5 2%

Number of Unsafe Condition 90 100

Number of Unsafe Acts 150 50

Number of Training 18 30

Why did we

perform bad ?

What we did good to achive the

target ?

Did we set right

target ?

Identfy the causes and

effects

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Phase 4 - Audit & Revision

M.Guneri / HS Mang.

Revision on Master Plan

ROUTE STEPSPhase I Phase II

2014 2015 2016 2017 2018 2019 2020 2021

1 Assess Current Situation

2 Restore Basic Conditions

3 Accident & Near Miss Analysis

4 Risk Analysis

5 Set up Data Collection

6 Proactive Work Place Improvement

7 Innovative Improvements

8 Eradicate a specific risk

9 Emergency Management Perfection

10 Behaviour Change Programmes

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Results

M.Guneri / HS Mang.

Automative Industry with appx. 700 employees

% 60 decrease in the number of accidents/Incidents

% 40 accident related property damage cost decrease

% 10 employee satisfaction increase

In 2 Years

Packaging Industry with appx. 300 employees

% 40 decrease in the number of accidents/Incidents

% 30 accident related property damage cost decrease

% 4 employee satisfaction increase

In 2 Years

Thank you

M.Guneri / HS Mang. 21