Making Zero Accidents A Reality

John Mathis

Bechtel Corporation

John Mathis

Bechtel Corporation

Making Zero Accidents A Reality

Project Team

Making Zero Accidents A Reality

Project Team

CPI Conference 2001

John Mathis

Bechtel

John Mathis

Bechtel

Making Zero Accidents A Reality

Making Zero Accidents A Reality Project Team

John J. Mathis Bechtel Corporation, ChairBill Alfera FPL EnergyAlan R. Burton Cianbro CorporationMike Cain Lockwood GreeneDennis Cobb DuPontPaul DeForge Ontario Power GenerationP. D. Frey Austin IndustriesJohn A. Gambatese Oregon State UniversityTom Hardesty Celanese AcetateJimmie W. Hinze University of FloridaScott Johnson Tyco/Grinnell Fire ProtectionRandy Marconnet Watkins Engineering & ConstructorsBill W. Poppell Florida Power & Light CompanyMichael F. Schwimmer ChevronGary L. Wilson NCCER

John J. Mathis Bechtel Corporation, ChairBill Alfera FPL EnergyAlan R. Burton Cianbro CorporationMike Cain Lockwood GreeneDennis Cobb DuPontPaul DeForge Ontario Power GenerationP. D. Frey Austin IndustriesJohn A. Gambatese Oregon State UniversityTom Hardesty Celanese AcetateJimmie W. Hinze University of FloridaScott Johnson Tyco/Grinnell Fire ProtectionRandy Marconnet Watkins Engineering & ConstructorsBill W. Poppell Florida Power & Light CompanyMichael F. Schwimmer ChevronGary L. Wilson NCCER

Plenary Session

• Take a safety journey.

•Review the project team mission.

•Review the research methodology.

•Reveal best practices identified.

•Provide examples of key findings.

•Provide overview of our Implementation Session.

• Take a safety journey.

•Review the project team mission.

•Review the research methodology.

•Reveal best practices identified.

•Provide examples of key findings.

•Provide overview of our Implementation Session.

Construction Industry Facts

• 636,000 construction companies

•>7,000,000 persons employed in construction

•Construction industry (risk)

- 18% of work-related deaths

- 15% of all workers’ compensation cases

•Approximately 1,000 construction workers killed each year

• 636,000 construction companies

•>7,000,000 persons employed in construction

•Construction industry (risk)

- 18% of work-related deaths

- 15% of all workers’ compensation cases

•Approximately 1,000 construction workers killed each year

Zero Accidents Study Findings – 1993

•High-impact zero accident techniques

- Pre-project/pre-task planning for safety

- Safety orientation and training

- Written safety incentive programs

- Alcohol and substance abuse programs

- Accident/incident investigations

•High-impact zero accident techniques

- Pre-project/pre-task planning for safety

- Safety orientation and training

- Written safety incentive programs

- Alcohol and substance abuse programs

- Accident/incident investigations

CII OSHA Recordable Performance1993-1999

CII OSHA Recordable Performance1993-1999

8.809.509.90

10.60

11.8012.20

Est.8.21

1.591.602.302.66

3.003.44

1.67

0

2

4

6

8

10

12

14

1993 1994 1995 1996 1997 1998 1999

527 613 644 770 518 765 995

Year and Work-hours (MM)Year and Work-hours (MM)

Recordable Incidence

Rate

Recordable Incidence

Rate

IndustryIndustry

CIICII

Note: Industry based on OSHA SIC 15

Note: Industry based on OSHA SIC 15

CII Lost Workday Case Performance

1993-1999

CII Lost Workday Case Performance

1993-1999

5.50 5.504.90

4.50 4.404.00 Est.

3.67

0.63 0.81 0.55 0.45 0.31 0.41 0.27

0

1

2

3

4

5

6

7

8

1993 1994 1995 1996 1997 1998 1999

527 613 644 888 591 763 1,122

Year and Work-hours (MM)Year and Work-hours (MM)

Lost Workday Case

Incidence Rate

Lost Workday Case

Incidence Rate

IndustryIndustry

CIICII

Note: Industry based on OSHA SIC 15

Note: Industry based on OSHA SIC 15

Zero Accidents – Revisited

5,148,000,000 work-hours worked by CII Member Companies

51% reduction in recordable injuries

What safety best practices have supported this improvement and are at the forefront

of safety management today?

Making Zero Accidents A RealityCII Project Team 160

Formed 1999

5,148,000,000 work-hours worked by CII Member Companies

51% reduction in recordable injuries

What safety best practices have supported this improvement and are at the forefront

of safety management today?

Making Zero Accidents A RealityCII Project Team 160

Formed 1999

Project Team Mission Statement

Make zero accidents a reality through

research and identification of current

Zero Accidents best practices that have

provided proven results across a broad

spectrum of the construction industry.

Make zero accidents a reality through

research and identification of current

Zero Accidents best practices that have

provided proven results across a broad

spectrum of the construction industry.

ExpandedProject Team Mission Statement

Develop a communication and

education component to assist in

understanding and implementation

of best practices that support

a Zero Accidents culture.

Develop a communication and

education component to assist in

understanding and implementation

of best practices that support

a Zero Accidents culture.

CII Zero Accidents Study 2000–2001

Methodology – two studies

- Large construction firms

- Large construction projects

Surveyed largest U.S. construction firms

- Based on 1999 ENR 400

- 400 surveys sent; 102 responses

Methodology – two studies

- Large construction firms

- Large construction projects

Surveyed largest U.S. construction firms

- Based on 1999 ENR 400

- 400 surveys sent; 102 responses

CII Zero Accidents Study 2000–2001

Detailed interviews on 38 North American construction projects ($50-$600 million):

- Petrochemical

- Industrial

- Public works

- Transportation

- Hotel-casino

- Commercial buildings

Detailed interviews on 38 North American construction projects ($50-$600 million):

- Petrochemical

- Industrial

- Public works

- Transportation

- Hotel-casino

- Commercial buildings

Nine Industry Best Practices

• Demonstrated management commitment

• Staffing for safety

• Safety planning

• Safety training and education

• Worker participation and involvement

• Recognition and rewards

• Subcontractor management

• Accident/incident reporting and investigations

• Drug and alcohol testing

• Demonstrated management commitment

• Staffing for safety

• Safety planning

• Safety training and education

• Worker participation and involvement

• Recognition and rewards

• Subcontractor management

• Accident/incident reporting and investigations

• Drug and alcohol testing

Best Practice Results

Over 30 key findings

revealed that companies

utilizing these best

practices have significantly

lower recordable injury

rates.

Over 30 key findings

revealed that companies

utilizing these best

practices have significantly

lower recordable injury

rates.

Zero Accidents Study2000-2001

Of the 38 construction projects

interviewed, four projects have

achieved zero accidents.

Of the 38 construction projects

interviewed, four projects have

achieved zero accidents.

Demonstrated Management Commitment

Top management participated in investigation of recordable injuries

Top management participated in investigation of recordable injuries

1.20

6.89

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

Reco

rdable

Inci

dent

Rate

Every Injury 50% or Less

1.2

6.89

Demonstrated Management Commitment

Company president/senior management reviews safety performance report

Company president/senior management reviews safety performance report

0.97

6.89

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

Reco

rdable

Inci

dent

Rate

Yes No

0.97

6.89

Worker Involvement and Participation

Management and supervisory personnel receive behavior overview training

Management and supervisory personnel receive behavior overview training

1.38

2.82

0.00

1.00

2.00

3.00

Reco

rdable

Inci

dent

Rate

Yes No

1.38

2.82

Safety Training and Education

Workers receive formal safety orientationWorkers receive formal safety orientation

1.51

3.80

0.00

1.00

2.00

3.00

4.00

Rec

orda

ble

Inci

dent

Rat

e

Formal Informal

1.51

3.80

Safety Training and Education

Every worker on site receives orientationEvery worker on site receives orientation

1.76

5.72

0.00

1.00

2.00

3.00

4.00

5.00

6.00

Rec

ord

able

Inci

den

t R

ate

Yes No

1.76

5.72

Safety Training and Education

Workers receive formal/standardized safety

orientation

Workers receive formal/standardized safety

orientation

1.51

3.80

0.00

1.00

2.00

3.00

4.00

Reco

rdable

Inci

dent

Rate

Formal Informal

1.51

3.80

Subcontractor Management

Subcontractors submit site-specific safety plans

Subcontractors submit site-specific safety plans

1.37

3.83

0.00

1.00

2.00

3.00

4.00

Reco

rdable

Inci

dent

Rate

Yes No

1.37

3.83

Recognition and Rewards

Your incentive program is based on zero accident

objective

Your incentive program is based on zero accident

objective

1.33

3.29

0.00

1.00

2.00

3.00

4.00

Rec

ord

able

Inci

den

t R

ate

Yes No

1.33

3.29

Making Zero Accidents A RealityImplementation Session

• Demonstrated management commitment

• Staffing for safety

• Safety planning

• Safety training and education

• Worker participation and involvement

• Recognition and rewards

• Subcontractor management

• Accident/incident reporting and investigations

• Drug and alcohol testing

• Demonstrated management commitment

• Staffing for safety

• Safety planning

• Safety training and education

• Worker participation and involvement

• Recognition and rewards

• Subcontractor management

• Accident/incident reporting and investigations

• Drug and alcohol testing

Implementation Session

• Panel presentation and discussion

• Review and discuss nine best practices that support Zero Accidents culture.

• Distribute “Making Zero Accidents A Reality” pocket card.

• Describe education module and best practice data sheets.

• Panel presentation and discussion

• Review and discuss nine best practices that support Zero Accidents culture.

• Distribute “Making Zero Accidents A Reality” pocket card.

• Describe education module and best practice data sheets.

0.00

1.00

2.00

3.00

4.00

Record

ab

le I

ncid

en

t R

ate

Project Safety Performance

Results of implementing best practices

Results of implementing best practices

2 workers per 1000

2 workers per 1000

Jobs thatImplemen

t a Few

Sample Mean

Jobs that Implement

Most

0.17

38 workers per 1000

38 workers per 1000

3.84

2.00

Accident reduction has improved significantly

since 1993, but we won’t just sit there.

Our workers are our key core competency.

We will continue to strive for Zero Accidents.

Accident reduction has improved significantly

since 1993, but we won’t just sit there.

Our workers are our key core competency.

We will continue to strive for Zero Accidents.

Even if you’re on the right track, you’ll get run over

if you just sit there.

Will Rogers

Even if you’re on the right track, you’ll get run over

if you just sit there.

Will Rogers

Construction Project Improvement Conference

Construction Industry Institute

Austin, Texas

2001: A Construction Odyssey

Trends and Perspectives

2001: A Construction Odyssey

Trends and Perspectives