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SENCO Construction Inc.
APPLICATION FOR THE ACCREDITATION OF SAFETY
PROGRAMS ON THE PRINCIPLES OF BEHAVIOR
SENCO Construction Inc.
Robinson Illinois Marathon Refinery
Robinson, IL.
2012
“Safe by Choice Leading By Example”
2
INDEX
Page Content
1 Application Cover Sheet
2, 3 Application Index
4 Company Information/Services
5 SENCO Safety Program Achievements
6 Description or Workforce/BEES Data Reports
7 BEES Data Reports/Feedback/Coaching Guide
8 SENCO Injury and Illness Data/Contact Information
9 SENCO Injury Illness Rate Information
10 Trend Injury Illness Rates
11 Trend Injury Information
12 Trend SENCO Safety Statistics
13 Trend Incident Rate vs. BEES Observations
14 Trend Observations to First Aids
15 Trend SENCO BEES Trended Data
16 SENCO Injury Man/Injury Descriptions 2012
17 SENCO Injury Man/Injury Descriptions 2011
18 SENCO Injury Man/Injury Descriptions 2010
19 BEES Program Overview SENCO BEES Program Overview/Belief’s/Data 6 Years
20 Significant Changes or Events
21 Significant Changes or Events Cont.
Management/Leadership and Employee Involvement
22 Goals, Objectives and Planning
23 Visible Top Management
Responsibility and Authority
Line Accountability
Employee Involvement
24 Employee Involvement Cont. Superintendents and
Foreman Responsibilities
25 BBS/BEES Training Program
3
26 SENCO BEES Steering Committee
Written Safety and Health Management System
Work Site Analysis
27 Routine Self Inspections
Hazard Reporting Systems for Employees
Industrial Hygiene Program
Investigation of Incident and Near Misses
28 Trend/Pattern Analysis
Hazard Prevention/Control
29 Hazard Prevention Control Cont.
Success Stories
30 Success Stories Cont.
Certification Signatures for Application
Page Description of Attachment
31, 32 Attachment A – SENCO Bees Observation Improvement Plan for 2012
33, 34 Attachment B – SENCO Texas Hold’em Card Game Rules
35 Attachment C – SENCO Texas Hold’em Card Game Tracking Sheet
36, 37 Attachment D – Sample BEES Steering Committee Meeting Notes
38, 39 Attachment E – Monthly BEES Observation Report (Participation)
40, 41, 42 BEES Program Comments Report
43, 44 Attachment F – SENCO BEES Observation Point Summary Report
45 Attachment G – SENCO Bees Coaching Guide
4
COMPANY Information
SENCO CONSTRUCTION INC. is a privately held Illinois corporation owned by Steven E. and Valerie J.
Neeley of Robinson, Illinois. Steve Neeley was employed by MAECO Inc. in 1975 and managed the Robinson
branch since its beginning in 1980 then became president in 1987 until his purchase of the Robinson facility in
February, 1995. During the past 17 years under Mr. Neeley’s leadership SENCO has experienced phenomenal
growth at Illinois Refining Division along with numerous safety and community awards. SENCO
CONSTRUCTION became the first VPP Star Contractor in the state of Illinois and was the recipient of
Marathon’s Living our Values award in 2006 to name a few.
The next page of SENCO history is soon to be written as Steve Neeley will be retiring from the company
effective June 30, 2012 and will soon pass the torch to its new co-owners, Resa J. Shaner and Chad A. Brown.
Resa has held the office of President at SENCO for the past six years, beginning her employment with SENCO
in 2002. Chad has extensive experience at Robinson refinery and was a local project manager for over 10
years. Chad brings a wealth of experience and knowledge to the company. The new co-owners share Steve
Neeley’s vision for safety, leadership, work performance and community involvement at Illinois Refining
Division and Robinson, Illinois.
SERVICES
SENCO CONSTRUCTION offers a broad line of services for new construction and plant maintenance
fields, including site work, concrete installation, structural steel erection and mechanical installation. As a
union contractor signatory with eight different crafts SENCO CONSTRUCTION offers a wide variety of
manpower options as well as a large inventory of heavy construction equipment available for bare rentals. A
maintenance shop is on-site and a full time staff is employed for on-sight equipment maintenance to ensure
safety and maintenance records and requirements are upheld.
SENCO CONSTRUCTION has a fabrication shop on site to facilitate fabrication of rebar, structural
steel, and piping spools.
SENCO CONSTRUCTION maintains a rigid safety environment. We employ a full time Safety
Superintendent, 2 Safety Technicians whose duties include record keeping, continually updating safety
programs, job site visits, job site audits, orientation of new employees, and other items of safety concern.
SENCO CONSTRUCTION also operates a Safety Annex facility where 2 trained health technicians can
perform Pulmonary Function Testing, Respirator Fit Testing, Audiometric Testing and Drug/Alcohol Testing
for several testing services
SENEX X-RAY COMPANY, a division of SENCO CONSTRUCTION offers a wide range of non-
destructive inspection services including computer radiography, industrial radiography, ultrasound testing, die
penetrate testing, magnetic particle testing. Senex also has available AWS-CWI’s to complete a total welding
inspection service.
SENCO CONSTRUCTION provides all manpower and equipment necessary to crush and size coke
from Marathon Petroleum Company’s (MPC) Coker Unit. Senco coke crushing operations are performed
daily, including holidays under a five year contract with MPC. A minimum of 23,000 tons is processed
monthly.
SENCO CONSTRUCTION is the EPA First Response equipment and manpower provider for Marathon
Petroleum Company Illinois Refining Division.
5
SENCO Safety Program Achievements
OSHA VPP STAR - August 2006 First Contractor in the State to Reach STAR Status
Successfully Recertified as OSHA VPP STAR in May 2010
Marathon Contractor Safety Excellence Award – SENCO has received the Marathon Contractor Safety
Excellence Award 5 times since the program started in 2005
Marathon Living Our Values Global Award – SENCO was awarded the Marathon Living Our Values Award
on April 3 2007
Illinois Refining Division VPP Outreach Award – SENCO was appreciated for the work in the VPP Outreach
Program and received the VPP Outreach Award for the year 2009
Robinson Chamber of Commerce Outstanding Business of the Year Award - SENCO was recognized as
the “Business of the Year” by the City of Robinson Chamber of Commerce in March 2009
Marathon Contractor Behavior Based Safety Program – SENCO entered into an agreement with Marathon
to participate in the Contractor Behavior Based Safety Program July 2006
OSHA VPPAC Member – SENCO became a member of the Voluntary Protection Program Association for
Contractors in 2008
OSHA VPP SGE Program – SENCO supports the OSHA VPP Program by supplying a SGE (Special
Government Employee) to assist OSHA Compliance Officers on site assessments for new and recertifying
companies for the OSHA VPP STAR program
6
DESCRIPTION OF WORKFORCE
SENCO Employees:
SENCO currently employs 94 union and supervision employees including 30 SENCO Company employees.
Age: The average age for SENCO employees is 42.7 years, with the range of ages being 19-63.
Length of Service: The average length of service for SENCO employees is 7.6 years, with the range being 0-37
years.
Union: SENCO has employees from 8 different unions.
SENCO BEES Data Types (Reports) BBS Reports: SENCO uses the Marathon ACTS program to input data and build reports through a website with
password protections. The reports are used in action planning and to raise awareness to behavior trends.
Common reports used include:
Area Reports: The Marathon Robinson refinery is broken into several areas. This report allows the user to
address issues that may only be present in a particular area. *See Attachment E and F for Example Reports.
Work Group Report: Workers are separated into five groups, based on job title. Reports are created for these
groups to raise awareness and give feedback specific to that group.
SENCO Internal Reports: SENCO also tracks reports of the trained observers and the comments made during
an observation. This is used to identify what areas need to be improved for data accuracy, and is a helpful tool
in the action planning process.
%Safe Rate: The ACTS process tracks and reports out the percent safe for all the Critical Behavior Indicators.
This measurement is a critical leading indicator and is used as follows:
100% Safe = Excellent safe work taking place
98% Safe = Good work, very few risks observed
95% Safe = May indicate a problem
90% Safe or lower = Very good indication of a problem or barrier to safe work
Safety Statistics: SENCO tracks a number of lagging indicators including:
OSHA Recordable Incident Rate (ORIR): This rate is tracked annually and is communicated to employees in
safety meetings, on the safety website, and on the digital communication board. This rate is calculated for
SENCO employees only.
Lost Time Incident Rate: This rate is also tracked annually and communicated each month.
Man Hours Worked: This statistic is necessary in order to determine our OSHA Recordable Rate. It is also
used to celebrate major milestones.
In an effort to bring attention to the injuries that occurred at the facility, especially first aid incidents, a visual of
the human body with injuries denoted as Blue/Orange/Red dots on the appropriate body parts was introduced.
This visually showed that the majority of injuries are hand injuries and led to the formation of the Hand
Protection annual compliance training topic and glove program.
7
Observations & Feedback: The SENCO BEES Observation process is voluntary; both becoming an observer
and being observed are optional. We ask all SENCO employees to attend training. The SENCO BEES
Observation Process also is a ―No Name, No Blame philosophy; observations are conducted and documented
without names. The process does not induce discipline, it asks for safe work. Employees are trained as
observers to sample the behaviors or actions that are taking place in the plant. They are volunteers trying to
make a safer workplace, utilizing what they know and communicating with each other. Leaders are asked to
engage this process and to lead with safety. It is believed that everybody working in this plant deserves to be
observed and should be able to perform a good day’s work as safely as possible.
SENCO observers are encouraged to use the SENCO Coaching Guide (Attachment G) to help fellow employees
get acclimated to performing observations; SENCO added the use of coaching guides in the New SENCO Texas
Hold’em Card game. See the game rules in Attachment B
See Attachment G – SENCO Coaching Guide Observations and feedback using the Coaching Guide are
conducted as follows:
Introduction: SENCO Coaching Guide
1. Introduce yourself and explain why you are there and what will happen.
2. Explain recording both safe and at-risk behaviors.
3. Show the data sheet and explain ―No Name-No Blame‖.
4. Explain you will be out of the way and efficient.
5. Let them know you will discuss the observation and the data sheet with them.
6. Stick to the subject at hand – stay focused.
7. Be positive, smile, make eye contact, and be confident.
8. Ask if they have any questions.
Feedback after the observation:
1. Show the data sheet as you explain it.
2. Reinforce safe behaviors first, give positive feedback.
3. Discuss any risks next, these are areas of concern.
4. The Observer’s role is to observe openly and give feedback, not change behaviors.
5. Give specific examples of safe, then at-risk behaviors.
6. Ask about anything you don’t understand, don’t make assumptions.
7. Do not place blame, avoid negative words and actions.
8. Allow employees to ask questions, give comments, or talk. Listen to them, take good notes. Encourage ideas
or suggestions for safer work.
8
Injury and Illness Data
Site Name: SENCO Construction
Calendar Year
Date
Submitted
2011
April 2012
Corporate Information
Name/Address SENCO Construction
1408 S Eaton
Robinson Ill 62454
Phone: 618-546-1485
Site Information
Address SAME
Phone: SAME
Company Owners
Steve Neeley
Resa J. Shaner Effective 07/01/12
Chad A. Brown Effective 07/01/12
Site Contact
Resa Shaner - SENCO Owner
Chad Brown-SENCO Owner
Curt Reimer - Safety
Superintendant
NAICS / SIC
237120/237
FAX
OSHA VPP Status
1-618-546-1120
STAR
# Applicable Union Contractors
2011
8
# Site Employees
Average/Month
123.6
Total
229
Total Hours Worked 2011
224,139
# Applicable Union Contractors
2010
8
# Site Employees
Average/Month
143.7
Total
284
Total Hour Worked 2010
281,414
# Applicable Union Contractors
2009
8
# Site Employees
107.8
Total
220
Total Hours Worked 2009
159,309
9
Injury & Illness Rate Information
Recordable Non-fatal Injury and Illness Case Incidence Rates
1
2
3
4
5
6
Year
2011
Total Work
Hours
Total Number of
Injuries & Illnesses
Total Case Incidence
Rate for Injuries and
Illnesses (TCIR)
Total Number of
Injury & Illness Cases
Involving Days Away
from Work, Restricted
Work Activity, and/or
Job Transfer
Days Away from
Work, Restricted
Work Activity,
and/or
Job Transfer Rate
(DART rate)
Year
2011
233789
0
0.00
0
0.0 Most recent published BLS rate for
NAICS code __237120___
3.8
1.9
1.2 % above or below National Average
100% Below
100% Below
100% Below
Year
2010
233789
2
1.42
2
1.42 Most recent published BLS rate for
NAICS code __237120___
3.8
1.9
1.2 % above or below National Average
62% Below
0.2% Over
15% Over
Year
2009
233789
0
0.00
0
0.0 Most recent published BLS rate for
NAICS code __237120___
3.9
2.0
1.3 % above or below National Average
100% Below
100% Below
100% Below
10
0.72 0.71 0.72 0.74
0
1.42
0 0 0
1.42
0 0 0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
2009 2010 2011 2012
Injury & Illness Rate Information
EMR
TCIR
DART
0.72 0.71 0.72 0.74
0
1.42
0 0 0
1.42
0 0 0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
2009 2010 2011 2012
Injury & Illness Rate Information
EMR
TCIR
DART
11
15
11
13
3
0
2
0 0 0
1
0 0 0
2
4
6
8
10
12
14
16
2009 2010 2011 2012
Injury Information
FIRST AID
RECORDABLE
LTI
15
11
13
3
0
2
0 0 0
1
0 0 0
2
4
6
8
10
12
14
16
2009 2010 2011 2012
FIRST AID
RECORDABLE
LTI
12
0.72 0 0
15
0 0 0.71
1.42 1.42
11
2 1 0.72
0 0
13
0 0 0
2
4
6
8
10
12
14
16
SENCO Safety Statistics
2009
2010
2011
2012
0.72 0.71 0.72 0.74 0
1.42
0 0 0
1.42
0 0
15
11
13
3
0
2
0 0 0
1
0 0 0
2
4
6
8
10
12
14
16
2009 2010 2011 2012
SENCO Safety Statistics
EMR
TCIR
DART
FIRST AID
RECORDABLE
LTI
13
0 1.42
0 0
2
6
10
3 4
11
23
20
15
11
13
3
0
5
10
15
20
25
2009 2010 2011 2012
Incident Rate-SENCO BEES Observation Rate
TCIR
Observations times 1000
# of Participants/3
First Aids
0 1.42
0 0
2
6
10
3 4
11
23
20
15
11
13
3
0
5
10
15
20
25
2009 2010 2011 2012
Incident Rate-SENCO BEES Observation Rate
TCIR
Observations times 1000
# of Participants/3
First Aids
14
15
11
13
3
4.906
11.78
19.62
5.81
0
5
10
15
20
25
2009 2010 2011 2012
Observation to First Aid Trend
First Aids
Short Shots X 500
15
11
13
3
0
5
10
15
20
25
2009 2010 2011 2012
Observations to First Aid Trend
First Aids
Short Shots X 500
15
0
50
100
150
200
250
300
SENCO BEES Trended Data
# of At Risk
Manhours X 1000
Hrs Between ShortShots
Short Shots X 50
0
50
100
150
200
250
300
1st Qtr 2ndQtr
3rdQtr
4thQtr
1st Qtr 2ndQtr
3rdQtr
4thQtr
1st Qtr 2ndQtr
3rdQtr
4thQtr
1st Qtr
# At Risk
Manhours
Hrs Between SS
# of SS
16
SENCO Injury and Incident Trending 2012
First Aid
Heat Exhaustion
OSHA Recordable
Back Side First Aid
First Aid Injury 2011 OSHA Rec
1 Abrasions 1 Contusions
1 Crushing Injury Foreign Body
1 General Medical
Laceration Puncture
Wound
6 Strain Sprain
1 Chemical Burn Fluid Burn
Thermal Burn
Flame Burn Dislocation
Fracture 2 Heat
8 Total Injury Types
13
Totals
17
SENCO Injury Trending 2010
First Aid
Heat Exhaustion
OSHA Recordable
Back Side First Aid
First Aid Injury 2010 OSHA Rec
1 Abrasions 1 Contusions
1 Crushing Injury 2 Foreign Body
General Medical
1 Laceration Puncture
Wound
3 Strain Sprain 1
1 Chemical Burn Fluid Burn
Thermal Burn
Flame Burn Dislocation
Fracture 1 1 Heat
6
Total Injury Types
2
11
Totals
2
18
SENCO Injury Trending 2009
First Aid
Heat Exhaustion
OSHA Recordable
Back Side First Aid
First Aid Injury 2009 OSHA Rec
2 Abrasions 2 Contusions
4 Crushing Injury 4 Foreign Body
General Medical
Laceration Puncture
Wound
2 Strain Sprain
Chemical Burn Fluid Burn
1 Thermal Burn
Flame Burn Dislocation
Fracture Heat
6
Total Injury Types
15
Totals
19
SENCO BEES (Behaviors Encouraging Employee Behavior) Observation Program Overview
SENCO BEES Steering Committee Belief’s
SENCO Steering Committee believes observations are an indicator (Trending Data) for
better protection of ALL employees at the MPC Facility. Reporting these indicators from the BEES Data helps to prevent future incidents and promotes preventative actions to eliminate or minimize “at risk” conditions.
SENCO Steering Committee believes it is worth the time and money for observations. By minimizing “at risk” situations, SENCO employees can reduce or eliminate injuries which can increase employee productivity and reduces medical expenses.
SENCO Bees Program Belief’s
SENCO believes active participation of all employees is a part of their daily job
function and should be incorporated into their work scope EACH day, performing a minimum of 1 observation each work day.
SENCO believes supervision is responsible to insure participation of all employees in the work groups in the BBS program and that will be a part of their job performance review by SENCO management each month and annually.
SENCO believes all work should be performed in a manner it would be done if supervision or safety were looking at the job - NO SHORTCUTS - NO EXCEPTIONS. We expect everyone to be responsible to make sure this is done with every job and make sure their co-worker is safe and goes home safe. It starts with each worker looking out for the other and thinking ahead of what can be done each time to keep a job task from becoming "at risk".
Addition of Incentives/rewards for employees who can perform the required amount of Observations per week (5)
SENCO BEES Observation Data
Year Number of
Observations
Average Number
Performed
in a Week
Number of At Risk
Observations
Percent at
Risk
Hours between
Observations
Man-hours
Worked
2006 665 13 85 13% 374 249,317
2007 974 19 164 17% 226 221,016
2008 3216 61 612 19% 61 197,218
2009 2453 50 102 4% 71 159,309
2010 5890 123 338 6% 48 281,414
2011 9810 200 454 5% 24 224,139
20
Significant Changes or Events
1. SENCO BEES Observation Improvement Plan 2011 SENCO Construction Management developed a
BEES (Behaviors Encouraging Employee Safety) Improvement plan for 2011. After reviewing observation
data for 2010 it was concluded that an opportunity for improvement was to motivate our SENCO middle
Management to promote participation in their work groups. In the 2011 Improvement Plan we targeted our
middle management to work with their work groups to help eliminate “At Risk” situations in the field by
performing observations. Working with SENCO’s Middle Management to allow time for employees to
perform observations was addressed. SENCO also asked for middle management to “Lead by Example”
by performing observation with or in front of their work groups. This has led to a 54% improvement in
employee participation to continue to make our work sites safer and reducing employee injuries.
*SEE Attachment A for 2012 BEES Observation Improvement Plan
2. SENCO Texas Hold’em Card Game in 2012 SENCO management wanted to increase participation in the
BEES Program without increasing the amount spent on incentives. SENCO believes everyone should want
to be safe and work safe, increases in the dollar amount of incentives seems to be a short term solution. As a
group it was decided to increase participation by making the program more fun. SENCO sent an hourly
employee to the National BBS Conference in RENO NV in 2011, one of the objectives was to look for ways
to make the observation program more fun. The Texas Hold’em card game was mentioned in one of the
sessions. The Texas Hold’em card game was accepted and improved upon to work well in the construction
industry and the results worked out well.
*SEE Attachment B SENCO Texas Hold’em Rules and Tracking Systems
3. SENCO strives continuously to improve hazard recognition; our hazard identification program is improved
and updated several times a year. This year we completely overhauled our PTHA (Pre Task Hazard Analysis)
Program. Each PTHA is printed on an 11x17 sheet of paper and they are packaged in glued booklets for easy
use, this also makes them more user friendly. We have designed job specific PTHA’s for general construction
jobs, HAZWOPER work and coke crushing facility tasks. Each of these PTHA’s has their own list of specific
hazards. On the PTHA’s all hazards can be listed and actions taken to minimize or eliminate hazards can be
recorded. We added a Walking and Working Checklist and a Post Job Safety Analysis section for
Superintendents to complete at the end of each day or job task so they are aware of issues or injuries that
might have happened on their jobs. Detailed training was completed by SENCO employees who are asked
to complete the PTHA’s. These PTHA’s are also audited monthly to ensure they are being completed for ever
job.
4. SENCO Training Center Usage In 2011 SENCO Construction encouraged all contractors and Marathon
employees to use the SENCO Training Center Facility. In 2011 it is estimated that over 11, 700 refinery
employees walked through the doors for training. Marathon used the facility for MSAT2 New employee
orientation, planning meetings and Safety 1st Training. Other contractors use the facility for safety training,
specialized training and VPP STAR Celebrations. The SENCO training facility is 200 seat building
designed for a learning environment that is conducive to excellent teaching and retention qualities for a safer
workforce. Safety training is normally suspicious in most injury or accidents and SENCO wants to help
provide quality training for everyone at the Robinson Refinery.
5. SGE opportunity, the SENCO Safety Superintendent had the opportunity to assist OSHA in a site VPP
Recertification. The ability to observe and review another company’s safety program became a learning
experience. Viewing different methods of obtaining safety excellence is a great help to improve safety
processes for everyone involved in the VPP program. Some of what was learned performing this audit was
implemented at SENCO to improve safety culture
21
6. BEES Steering Committee One of the goals for the SENCO Bees Steering Committee was to produce an
Observation Awareness Video, use it to motivate participation in the SENCO Observation program. The
video was completed in April of 2012
Management Leadership and Employee Involvement
Management Commitment to Safety/Health Protection and to the SENCO Observation
Program
SENCO management is in complete support for the Safety and Health policies and BEES Observation
programs, this is demonstrated through financial support and being highly involved with all of the program
processes, Management supports the BEES observation program by being involved in the implementation of the
program, support employees by allowing time away from their job to perform observations and plan incentive
programs that would reward employees who perform observations as implied. Management should show
support by recognizing a job well done. SENCO management also monitors the progress and development of
the program to ensure continuous improvement. SENCO management is continuously involved with program
improvement, enforcing observation policies and requesting employee participation to ensure each employee
has a safe place to work.
SENCO management and employees promote a safe work environment by developing communications and
helping to reduce risk for all employees by looking for At Risk conditions and minimizing that risk by using
BEES Observations or just intervening to eliminate potential injuries. By being proactive in safety to help lower
injuries we can lower risk and lower injury rates to ensure a safe work environment for all employees.
SENCO management also supports the BEES program by allowing Steering Committee Members to meet
bi-weekly on Wednesday Mornings for 30 minutes after our safety meeting, things change quickly here that the
Marathon facility, bi-weekly meetings are required to keep employees informed of changes and to allow sufficient
time to inform all employees on the BEES program updates and improvements.
The SENCO safety department will provide observer training to all employees, work with employees to help
improve the program, hold BEES Observation committee meetings, communicate BEES program success and
chances for improvement, trend BEES Data and communicate to employees for improvement, improve the
quality of the observations, attend all BBSCAPS meetings at Marathon, also help promote the Observation
program outside of Marathon when required.
Employees are asked to perform at least 5 observations per week; this would include 1 for the weekly
BEES Blitz. Employees are to complete BEES Observation training and to perform quality observations as time
allows. Employees are asked to give their observation to SENCO Safety Technicians or Superintendents, the
observation the go to the SENCO receptionist to have the data entered into the ACTS Software system.
Policy
SENCO Management and Safety Department have developed the SENCO BEES Observation Program Policy
SSP-58, it details program requirements and goals
22
Goals, Objectives, and Planning
SENCO goals for 2011 were 90% complete; objectives and plans for the BEES Observation program are based
on the results from the previous year’s Observation Data and Improvement Plan. Some Goals for 2012 include.
Produce a SENCO Bees Observation Program Video.
Update and/or rebuild the Observation Coaching Guide, make it more user friendly, Provide Training
Become accredited with the Cambridge Institute.
Define Budget Guidelines for BEES Program
Develop BEES Steering Committee Goals
Increase participation
Start up a BEES Observer Recognition Bulletin Board in the Safety Training Room, use pictures and
posters for employee recognition. Contact business or presenters from the Reno Conference to see what
they do to recognize good observers or good observations.
Include Marathon Representatives in our BEES Program
Invite Ray Brooks, Tim Meier and Monica Piper randomly to the SENCO BEES Steering Committee
meetings to support the BEES Steering Committee and provide input
Special Task’s for the SENCO BEES Steering Committee/Program
Get the office personnel trained and performing Observations
Find a good way for the Garage operators to get their observations to SENCO and MPC instead of just
MPC so they can be included in the SENCO Texas Hold’em Card Game
Steering committee to build a BEES MONTHLY Newsletter? Possibly give to MPC to help motivate
their program?
Implement the new SENCO Texas Hold’em card game.
Track and set up BEES observation Training to achieve 100% trained work force.
Things we can do to get better participation and increase the opportunities to reduce hazards
1. Quick Fire- for target observations. Observations need to be treated as a daily requirement.
2. Buddy program-to perform comparison observations.
3. Create a list of items that are considered general hazards.
4. Superintendents-Give employee’s permission to perform an observation.
5. Superintendents- Ask them to perform an observation on Safety Wednesday; it will be covered at the safety
meeting also
6. All SENCO Supervision-Lead by example; let your workers see you performing observations as a
Superintendent
7. SENCO Safety to perform plant walks and perform observations
8. SENCO Safety- Take pictures of employees performing observations, use them in training packages
9. SENCO Safety- More recognition for employee who write quality observations, pictures, point out quality
observation at safety meetings.
10. SENCO Management- Provide a $50 dollar bill and 2 gift Certificates for the Monthly BEES Drawing
*Attachment D for recent BEES steering committee meeting notes
23
Visible Top Management Leadership
SENCO Management and Safety Department ensures that all employees are actively involved in SENCO BEES
Observation program by allowing SENCO employees to be part of the decision-making and problem solving.
These may include active participation in analyzing hazards and planning activities to heighten safety and health
awareness. Management encourages employees’ involvement and devises appropriate recognition for outstanding
employee participation including incentives, recognition and appreciation for outstanding observations and/or At
Risk conditions caught and eliminated. The BEES Program Promotion / Recognition Program has been discussed
with all employees so that they have a complete understanding of this program. Recognition Programs are re-
evaluated monthly at safety meetings to ensure effectiveness.
Responsibility and Authority
Each employee is designated the responsibility for their own safety. They have demonstrated pride in their work.
Employees are given control of the day-to-day work load and the elimination of hazards. Although they are
required to report issues to management, employees are expected to eliminate safety threats before they report.
If they cannot eliminate these threats they are expected to STOP THE JOB and contact their superintendent or the
SENCO safety department to put into place interim controls. Each employee has been open to discussing issues
and asking questions with management, which leads this to be an area of excellence for SENCO Construction.
Line Accountability
All SENCO management employees are evaluated on a continuous basis, including managers, supervisors and all
field employees. Observation data is trended, analyzed and reported to all SENCO employees once a month.
SENCO started using the “Observations by Work Groups” Spread Sheet, in this spread sheet participation by work
group is provided by Superintendent, we use Percent Participation, Employees on the Payroll to demonstrate which
groups are performing observations by providing a Percentage of employees who completed an observation.
Employee Involvement
In 2011, SENCO Constructions employee’s involvement remains one of its areas of excellence. Employees are
involved in the support of the BEES observation program through communication, meetings, and formal on the
job training. Employees attend the weekly safety team meetings where the training package included reminders to
perform observations; SENCO also holds a monthly meeting for the SENCO Bees Observation program updates
and contest completion. During this meeting employees are involved in the BEES Observation process. SENCO
uses this meeting to communicate any findings from the trended data, participation and quality observations,
discuss any safety concerns they may have, and receive safety policy training.
Although not all employees are observers, all employees have the following responsibilities to the process.
1. Seek to understand the Observation Data sheet and definitions.
2. Be open to observation and consider being trained as an observer. If further interested, inquire about
becoming a committee member.
3. When given feedback, realize the safe work observed, and any at-risk behaviors that are within your power to
correct. After the observation occurs, ask for feedback if it isn’t given.
4. Communicate unsafe conditions and inadequate management systems through work orders, suggestions, and
the comments section of the Observation data sheets.
5. Actively participate in the BEES program by discussing the observation data, identifying problem areas,
developing action plans, and helping to carry out the action plan.
24
6. Seek to understand the observation process and ask questions.
7. Don’t ignore at-risk behaviors being performed by other people. Show concern about their safety and the
potential for an accident by pointing out at-risk behaviors. Provide positive reinforcement for safe behaviors.
8. Be a safety role model by following safety rules and procedures, and wearing proper PPE for your protection.
9. Be supportive, cooperative, and open minded toward observers.
10. Don’t consider the observers as problem solvers; continue to use the refinery’s systems to resolve problems.
Superintendents and Job Foreman are also critical to the process. Their responsibilities include:
1. Seek to attend Behavior Based Safety and Observer Training and actively participate in the learning.
2. Provide time and coverage for BEES observation team members to attend training, meetings, and do other
team business, including observations.
3. Provide time for observers to do observations. Meet with the observers to discuss issues they may have and
determine ways to assist them.
4. Maintain anonymity of the observation process. For instance, seek to improve conditions by offering positive
suggestions derived from our BEES Data.
5. Help manage resistance to change (get information about what is happening with this process to everyone).
Discuss observer concerns with the crew and make sure the crew knows observations are part of everyone’s job.
6. Review the ACTS data reports, and use this data pro-actively in safety meetings. Follow up on any action
items or suggestions to minimize at-risk situations or behaviors.
7. Do NOT give up safety responsibility. Continue to perform all of your normal safety related jobs, including
holding people accountable for working safely.
8. Be a safety role model: wear proper protective equipment and continue to follow all safety policies. Lead by
example.
9. Understand the observation process, learn the critical behavior definitions, know the steering committee
members and seek them out regarding questions or concerns about the process.
10. Talk with each observer in your work group personally at least once per week, encouraging the observer and
offer help to achieve observation goals.
11. Provide consistent (soon, certain, positive) feedback for safe work or safety ideas when appropriate.
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BBS TRAINING PROGRAM
Training Methods Behavior Based training was developed by the Marathon BBSCAP team. SENCO performs training for
employees on an as needed basis. The class is 4 to 5 hours long and is limited to 15 individuals. Course content
includes:
SENCO Program Goals
SENCO BEES BBS Concepts, Principals and Process
SENCO JHA’s
Work Clearance Permits
Influences on our Decisions
The Science of our Behaviors
Consequences of our Actions
Summary of Awareness
Short Shot Program
Definitions
Observation Form
Procedures
Work Environment
Tools and Equipment
PPE
People
Safe or At Risk Presentation/Hazard Recognition Skills
Barriers to working safely
Feedback Awareness
Things to avoid
Types of Observations
Resistance
Practice conducting observations in the field
All employees and contractors are highly encouraged to attend a class.
In addition to training for observers, the Steering Committee believes they must also continually develop their
knowledge and skills. This is accomplished through:
BBS conferences
Meetings to share best practices and barriers
Benchmarking with other facilities
Meetings with Marathon Observation Employees
BBS Newsletters
26
The SENCO BEES Steering Committee: The committee is made up of hourly employees who are trained
observers, who are in good standing. The committee is made up of employees from different areas and work
groups to guide the process. SENCO Management attended the BEES meeting and supports the process
completely. This committee meets bi-weekly to review data, assess the process, and discuss action plans and
goals. Their responsibilities are to:
1. Attend training
2. Attend all committee meetings, whenever possible.
3. Recruit observers.
4. Help conduct kick-off meetings or other presentations when asked.
5. Assist with training classes when asked.
6. Maintain observation skills by meeting observation goals.
7. Act as coach/mentor to all observers.
8. Review observation data regularly and provide feedback to all observers.
9. Use data to form action plans or follow up items.
10. Promote and help sustain the BEES Observation process
The SENCO BEES Steering Committee also has a member who is a SENCO Employee, The SENCO Safety
Superintendent attends meeting to help keep the Steering Committee Focused and track progress. They are
responsible to;
1. Assist committee members to obtain necessary resources, such as office space, supplies, additional training,
manpower, etc.
2. Have regular contact with all committee members.
3. Serve as liaison between management and the committee. Represent management’s point of view to
committee, and vice versa. Bring committee concerns and views to other managers.
4. Support and advocate the process with managers.
5. Review committee progress relative to timeline. Assist in problem solving as needed to maintain progress and
achieve process goals.
Written Safety and Health Management System
A Safety Improvement internal assessment program is currently being implemented and used for all safety and
health programs; the latest being completed in January 2011 for the 2012 year. These assessment results will be
placed into a summary document. This summary allows each deficiency to be documented and the site safety
manager then develops an action plan to track issues to completion. A monthly review of progress is reported to
the SENCO management team. Completion of the deficiencies identified in the last assessment 2011, is a goal
for 2012.
Worksite Analysis
Hazard Analysis of Routine Jobs, Tasks, and Processes Our Job Hazard Analysis (PTHA Pre Job Hazard Analysis) is a tool we use for jobs in the Marathon Facility.
SENCO employees are required to use these PTHA’s before any job or task is started then daily as long as the job
lasts. These PTHA’s are used to identify hazards associated with jobs SENCO employees perform. These are
explained in detail with all employees on the job and signed off before work can begin. These PTHA’s are audited
monthly for proper completion and to ensure they are completed for every job performed by SENCO employees.
27
Routine Self-Inspections
Required regular inspections of heavy equipment are being completed and reports are kept at the SENCO Shop
Location. SENCO in 2011 developed and implemented a Targeted Assessment Policy where SENCO Safety
Tech’s are asked to perform these targeted assessments each week. The reports are turned in to the SENCO Safety
Superintendent and SENCO Management for review. When this report is reviewed, SENCO management is to look
for noncompliance issues and determine corrective actions.
Quarterly Facility Safety Audits are performed on all four SENCO sites that are exterior to the Marathon Facility,
action plans are built for the issues noted on the facility audits for tracking to completion. We also complete job
site safety reviews randomly. The goal in 2012 continues to be to complete all inspections and complete the
implementation of controls.
Hazard Reporting System for Employees
Safety Suggestions, Employee Safety meetings, BEES Observations, Daily Job Safety Reviews, PTHA’s, Biweekly
Contractor Safety meetings, STEP safety meetings. SENCO management and Safety team members attend these
safety meetings at Marathon, Quarterly Contractor Safety Counsel. Safety Suggestions and Safety Opportunities
Shared (SOS) are some methods used to initiate corrective measures. This information gets emailed to employees
or covered at weekly safety meetings. At any time, any refinery or contractor employee can bring up a safety issue
and get a solution to the problem.
Industrial Hygiene Program
SENCO Construction has built a detailed Industrial Hygiene Monitoring Program. SENCO uses our Insurance
provider Laboratory Services. With the assistance of laboratory chemist and IH Professionals a monitoring plan
was developed. OSHA and NIOSH methods are using for Reference Methods of testing. The results are checked
for possible exceedance of OSHA PEL, Action Limits and or IDLH.
Monitoring is performed for
Noise Exposure So2 Mercury
Welding Vapors (Heavy Metals) Total Particulate Respirable Particulate
Poly Nuclear Aromatic Hydrocarbons/Benzene Soluble Carbon Monoxide Silica
Benzene/Voc
We complete annual audiograms for employees exposed to high sound levels. Respirator fit testing and PFT’s are
completed on an annual basis for employees who are required to wear respirators for their job tasks. Respiratory
Protection training was performed in 2011.
SENCO also has a plan to perform air testing for Benzene around employees who might be exposed to Benzene
during routine job tasks. SENCO has purchased 3 Rae Systems, Mini Ultra Rae monitors to perform air monitoring
for VOC’s. SENCO also purchased 3 Rae Systems Ultra Rae Benzene Monitors to monitor any excavation we
perform in the Refinery.
Sound Level Surveys were completed in 2009 and will need to be completed again in 2012
Investigation of Incidents and Near Misses
The SENCO Accident Investigation Policy has been revised to include responsibilities; the policy was also
updated to include a list of employees who will attend the investigation meetings. The new procedure has a
better outline for investigations and is used for Equipment Damage, Near Misses (that are serious) and injuries
28
Trend/ Pattern Analysis
Injuries and illnesses are trended within the Marathon facility and reported to all contractors through Marathon
STEPS (System To Ensure Participation Safely) meetings on a monthly basis. SENCO also trends First Aids and
injuries and takes corrective actions on trends that show at risk hazards.
We also use our BEES observation data to trend At Risk conditions and take appropriate actions. We determine
“Leading Indicators” “At Risks” Employee Participation as a company and by work groups by analyzing the BBS
data.
Hazard Prevention and Control
Hazard Elimination and Control Methods - Engineering Controls
SENCO uses Pre Task Hazard Analysis Reports (PTHA’s) and Daily Job safety Reviews to identify hazards with
each job, these same documents also list how to minimize the hazards listed on these reports. Our BEES
Observation program is also designed to reduce or eliminate hazards as they are identified
- Personal Protective Equipment
PPE used at SENCO Construction is adequate for the hazards present and are continuously being updated.
Trending through Injuries, Observations and employee input helps us to determine what needs to be changed
or improved with the PPE.
-Occupational Health Care Program
The employees have access to an Emergency Room and or nurse at the Crawford County Memorial Hospital at
any time they are needed. SENCO now staff’s two Safety and Health Technicians who are qualified to give first
aid and make recommendation if an injured employee required further medical attention. We can also use the
plant nurse at the Marathon facility for minor injuries and First Aid
-Preventive/Predictive Maintenance
The SENCO Maintenance performs Preventative and Predictive Maintenance on all of our own heavy equipment
as scheduled, maintenance reports are kept at the SENCO shop. Safety supplies maintenance is being addressed
currently; we are planning to continue fall protection, respirator cleaning, and sling inspections in early 2012
Safety and Health Training
SENCO Management
Managers are required to receive the same safety and health program training as the employees at the same time.
This is performed weekly at our Weekly Safety meetings; everyone on the payroll is required to attend these
meetings
Employees
Employees are required to attend weekly safety meetings that are 30 minutes in duration. SENCO employees are
also required to complete specialized training for certain task, such as; Fork Lift, AWP, PIV, HAZWOPER 40
Hour, HAZWOPER 8 Hour, Signal Person Training, Rigging, BEES observations and all required safety policies
29
Emergencies
All employees were trained on Marathon Facility emergency procedures. Plant Evacuation Drills are held annually
with a critic session after every drill to find deficiencies and correct any issues found. All employees participate
with corrective actions and implementation of policy changes. All suggestions were evaluated and most were
implemented.
PPE
Training on required PPE is included in the required topics for each employee. PPE policies and requirements are
also covered in the SENCO New Employee Orientation.
Sub-Contractors
All Subcontractors that work for SENCO must complete all training, orientations and testing is required to gain
access the plant. They adhere to all SENCO safety policies and procedures and get pre-approved to perform work
in the facility..
Success Stories
Safety culture of SENCO employees; SENCO employees have continued to show an improvement in
safety culture. Employees are asking more questions, looking for answers and getting help when needed.
Employees complete and discuss PTHA’s on a Daily basis before each job starts. Employees complete and use
daily prestart checklist to ensure equipment is safe and to get it fixed if it’s not working properly. We continue to
see over70% participation in the SENCO BEES observation program.
Middle management has taken this lead and has promoted safer working practices with their work
groups. During their site visits they identify hazards and eliminate risk to protect workers. SENCO
middle management has also been included in the 2011 BEES Observation Improvement Plan. They have
improved the observation program by leading by example, allowing their work groups the time to
perform observations and promoting the observation program over all.
SENCO management has supported the initiative to get the middle management personnel to get on
board with safety guidelines and the SENCO BEES Observation program by setting standards and requirements
for Superintendents and Job Foreman.
SENCO management has been involved with installing Sea Vans in the facility to help workers stay
better organized, to have a good storage area and making it safe to move equipment and tools without leaving
the facility. Having these sea vans in the facility has also helped with ergonomic issues since they have shelving
units and storage areas built into them.
SENCO Management has also built a New SENCO fab shop for Ironworkers and Pipefitter to work
that is designed to help eliminate unsafe conditions related to welding, grinding and cutting. The building has
new “Smoke Eaters”, Air filtration systems to prevent welding or cutting fumes from building up in the building
SENCO Construction has also purchased software for a computer to track when our employees bump
test their H2s Monitors monthly, this is hard to enforce and track without this software. Employees are now
tracked on a weekly basis to ensure their H2s monitors are being checked per owner’s recommendations.
Employees are encouraged to keep their H2s Monitors checked for proper operation. If this continues to be an
issue with a certain employee(s) there are disciplinary actions associated with non-compliance.
30
The SENCO Safety Department has been expanded to meet the safety needs and medical
surveillance requirements for all SENCO employees. SENCO management has made the commitment to have
1 Safety Manager, 2 Safety and Health Technicians and 2 Safety Technicians on site to manage the safety
and wellbeing of all employees. Having a safety program with health and safety specialist allows SENCO to
ensure employees are being monitored as required, injuries to be addressed and evaluated quicker, speed up
injury recovery and improve the loss of employee productivity. SENCO Safety can perform Pulmonary
Function Testing, Drug and Alcohol testing, Hair Follicle tests, Respirator Fit Testing and Audiometric testing
for SENCO employees and other contractors at the Marathon Facility.
Resa Shaner
Chad Brown
Curt Reimer
Safety Superintendent
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Attachment A - SENCO BEES Observation Improvement Plan 2012
SENCO BEES observation program Improvement Plan for 2012
SENCO BEES Steering Committee Belief’s SENCO Steering Committee believes observations are an indicator (Trending Data) for
better protection of ALL employees at the MPC Facility. Reporting these indicators from the BEES Data helps to prevent future incidents and promotes preventative actions to eliminate or minimize “at risk” conditions.
SENCO Steering Committee believes it is worth the time and money for observations. By minimizing “at risk” situations, SENCO employees can reduce or eliminate injuries which can increase employee productivity and reduces medical expenses.
SENCO Bees Program Belief’s SENCO believes active participation of all employees is a part of their daily job
function and should be incorporated into their work scope EACH day, performing a minimum of 1 observation each work day.
SENCO believes supervision is responsible to insure participation of all employees in the work groups in the BBS program and that will be a part of their job performance review by SENCO management each month and annually.
SENCO believes all work should be performed in a manner it would be done if supervision or safety were looking at the job - NO SHORTCUTS - NO EXCEPTIONS. We expect everyone to be responsible to make sure this is done with every job and make sure their co-worker is safe and goes home safe. It starts with each worker looking out for the other and thinking ahead of what can be done each time to keep a job task from becoming "at risk".
Addition of Incentives/rewards for employees who can perform the required amount of Observations per week (5)
Things we can do to get better participation and increase the opportunities to reduce hazards
1. Quick Fire- for target observations. Observations need to be treated as a daily requirement.
2. Buddy program-to do comparison observations.
3. Create a list of items that are considered general hazards.
4. Superintendents-Give employee’s permission to perform an observation.
5. Superintendents- Ask them to perform an observation on Safety Wednesday; it will be covered at the safety
meeting also
6. All SENCO Supervision-Lead by example; let your workers see you performing observations as a
Superintendent
7. SENCO Safety to perform plant walks and perform observations
8. SENCO Safety- Take pictures of employees performing observations, use them in training packages
9. SENCO Safety- More recognition for employee who write quality observations, pictures, point out quality
observation at safety meetings.
10. SENCO Management- Provide a $50 dollar bill and 2 gift Certificates for the Monthly BEES Drawing
32
Special Task’s for the SENCO BEES Steering Committee
Get the office personnel trained and performing Observations
Find a good way for the Garage operators to get their observations to SENCO and MPC instead of just MPC so
they can be included in the SENCO Texas Hold’em Card Game
Steering committee to build a BEES MONTHLY Newsletter. Possibly give to MPC to help motivate their
program?
Implement the new SENCO Texas Hold’em card game.
Track and set up BEES observation Training to achieve 100% trained work force.
BEES Steering Committee Goals for 2012
Produce a SENCO Bees Observation Program Video.
Update and/or rebuild the Observation Coaching Guide, make it more user friendly, Provide Training
Become accredited with the Cambridge Institute.
Define Budget Guidelines for BEES Program
Develop BEES Steering Committee Goals
Increase participation
Start up a BEES Observer Recognition Bulletin Board in the Safety Training Room, use pictures and posters for
employee recognition. Contact business or presenters from the Reno Conference to see what they do to
recognize good observers or good observations.
Include Marathon Representatives in our BEES Program
Invite Ray Brooks, Tim Meier and Monica Piper randomly to the SENCO BEES Steering Committee meetings
to support the BEES Steering Committee and provide input
33
Attachment B - SENCO Texas Hold’em Card Game
SENCO Texas Hold’em Game Rules
1. Use the best 5 of the cards you draw
2. 10 cards possible
3. Ways to draw a card, employee will always draw from a full deck
You get
2 cards for a Self-Observation Limit one Self Observation per month
2 cards for a Completed Coaching Guide Limit one Completed Coaching Guide Per Month
2 Cards for being current with your H2s Monitor Limit 2 cards per month
Bump Test the day of the BEES Safety Meeting
4 cards for completing 5 observations per Week Limit 4 cards a month
In that Month
4. You must have obtained 5 cards for the month to be involved in the BEES Update Safety meeting
Contest. You will get to draw 4 cards for completing 20 observations in the previous month, then you have
the chance to get 2 more cards for having a current bump test on your H2s Monitor.
5. The final 6 cards will be drawn when SENCO verifies you have completed 20 observations and prior to the
BEES Safety Meeting held monthly.
6. The 4 Best hands will be shown at the BEES Update Monthly Safety Meeting with prizes awarded then.
7. You will be required to select the 5 best cards in your hand to enter into the contest
8. Prizes for 1st, 2
nd and 3
rd will be awarded. 1
st place $50.00 bill, 2
nd and 3
rd will be gift certificates
9. If you wish to not be in front of the group to draw your cards, a SENCO Office employee will be selected to
draw your cards for you.
10. See any SENCO Safety Department Representative to draw your cards
34
Winning Hands in order, Highest to Lowest
Tie Breaker- if employee hands end in a tie, the highest card of played cards will win, if this still results in a tie
each employee will pull one card each, the high card will win.
Royal Flush This is the best possible hand in standard five-card Poker. Ace, King, Queen, Jack and 10, all of the same suit.
Straight Flush Any five-card sequence in the same suit (e.g.: 8, 9, 10, Jack and Queen of clubs; or 2, 3, 4, 5 and 6 of diamonds).
Five of a Kind All five cards of the same value (e.g.: 8, 8, 8, 8, 8; or Queen, Queen, Queen, Queen, Queen).
Four of a Kind All four cards of the same value (e.g.: 8, 8, 8, 8; or Queen, Queen, Queen, Queen).
Full House Three of a kind combined with a pair (e.g.: 10, 10, 10 with 6, 6; or King, King, King with 5, 5).
Flush
Any five cards of the same suit, but not in sequence (e.g.: 4, 5, 7, 10 and King of spades).
Straight Five cards in sequence, but not in the same suit (e.g.: 7 of clubs, 8 of clubs, 9 of diamonds, 10 of spades and Jack of diamonds).
Three of a Kind Three cards of the same value (e.g.: 3, 3, 3; or Jack, Jack, Jack).
Two Pair
Two separate pairs (e.g.: 2, 2, Queen, Queen).
Pair Two cards of the same value (e.g.: 7, 7).
High Card If a Poker hand contains none of the above combinations; it's valued by the highest card in it.
35
Attachment C - SENCO Texas Hold’em Card Tracking Spread Sheet
SENCO Texas Hold 'Em Month:____________
Participant Name
Coaching Guide
Self Observation
20 Observations Completed for Month
Current H2S Bump Test
♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠
♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦
Participant Name
Coaching Guide
Self Observation
20 Observations Completed for Month
Current H2S Bump Test
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
Participant Name
Coaching Guide
Self Observation
20 Observations Completed for Month
Current H2S Bump Test
♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠
♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦
Participant Name
Coaching Guide
Self Observation
20 Observations Completed for Month
Current H2S Bump Test
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
Participant Name
Coaching Guide
Self Observation
20 Observations Completed for Month
Current H2S Bump Test
♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠ ♥
♠
♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦ ♣ ♦
Participant Name
Coaching Guide
Self Observation
20 Observations Completed for Month
Current H2S Bump Test
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
36
Attachment D - Sample BEES Steering Committee Meeting Notes
BEES Steering Committee Meeting
April 18, 2012
In Attendance: Curt Reimer, Donnie Watts, Randy Brackett, Jim Wampler, Roger Beucherie, Resa Shaner,
Chad Brown and Mandy Hale.
Absent: Jeff Meehan, Brian Rauch, Brad Reinbold and Matt Miller.
Special Task’s for the SENCO BEES Steering Committee:
BEES Monthly Newsletter
Get the office personnel trained and performing Observations
Curt said Mick can help us put together videos for the program like they used to for the Bee’s Blitz
video.
Update and/or rebuild the Observation Coaching Guide, make it more user friendly, provide training.
Track and set up BEES Observation Training to achieve 100% trained work force.
Summer of 2012 SENCO to try to become accredited with the Cambridge Institute.
BEES Observer Recognition Bulletin Board in the Safety Training Room is up to display pictures for
employee recognition. Recognize one employee a week during safety meeting. Contact business or
presenters from the RENO Conference to see what they do to recognize good observers or good
observations. We have CD copies of the Reno training information. If any pictures taken inside MPC
will have to have a work permit.
Better participation and increase the opportunities to reduce hazards:
1. Quick Fire- for target observations. Observations need to be treated as a daily requirement.
2. Buddy program-to do comparison observations.
3. Create a list of items that are considered general hazards.
4. Superintendents-Give employee’s permission to perform an observation.
5. Superintendents- Ask them to perform an observation on Safety Wednesday; it will be covered at the safety
meeting also
6. All SENCO Supervision-Lead by example; let your workers see you performing observations.
7. SENCO Safety to perform plant walks and performs observations
8. SENCO Safety- Take pictures of employees performing observations, use them in training packages
9. SENCO Safety- More recognition for employee who write quality observations, pictures, point out quality
observation at safety meetings.
10. SENCO Management- Provide a $50 dollar bill and 2 gift Certificates for the Monthly BEES Drawing
BEES Steering Committee Goals for 2012
SENCO Safety-take pictures/videos of employees performing observations, use them in training
packages. Produce a SENCO Bees Observation Program Video. Mick will help with this.-Wok in
progress.
Update and/or rebuild the Observation Coaching Guide, make it more user friendly, Provide Training-
Done
Become accredited with the Cambridge Institute in 2012-build application and start assessment.
Define Budget Guidelines for BEES Program
Develop BEES Steering Committee Goals
Increase participation
Start up a BEES Observer Recognition Bulletin Board in the Safety Training Room, use pictures and
posters for employee recognition. Contact business or presenters from the Reno Conference to see what
they do to recognize good observers or good observations
37
Include Marathon Representatives in our BEES Program. Invite Ray Brooks, Tim Meier and Monica
Piper randomly to the SENCO BEES Steering Committee meetings to support the BEES Steering
Committee and provide input-Work in Progress.
Meeting Notes:
Committee discussed plan of action to be proactive for the “What if” scenarios for the upcoming
holidays (Memorial Day, 4th
of July and Labor Day). Randy said they will mention the “What if”
scenarios again during the tool box meeting. We could use the STAY FOCUSED slogan for Safety the
weeks of the holidays. See about moving the Safety meeting on Friday before Memorial Day (Safety
Friday) to be able to refocus our efforts, possibly do a walk thru on 2:30 pm on Friday, May 25th
. Or
have Safety Meeting on Tuesday, May 29th
after returning from long week-end to refocus. Resa said she
didn’t foresee that being a problem just need to let Marathon and Garage know. Donnie mentioned
maybe get hard hat stickers like the STOPWORK stickers but say STAY FOCUSED.
Committee reviewed the Observation Coaching Guide we should add what we expect out of quality
observations and add environmental for tools.
Monthly BEES Safety Committee newsletter going good. Resa mentioned to add observation data and
hours between observations in the newsletter.
Wall of Fame-Randy Brackett mentioned that Mike England had asked why his name was not on there.
Mike does have quantity in short shot observations but the wall of fame is for those that have quality
observations comments added.
Resa asked Mandy to email Chad and her list of employees that still need to be trained on the BEES
training. Update-emailed the list to Chad and Resa on 4/18/12. We need to work on Don and Gail’s
groups on doing short shots.
Committee viewed the BEES Observation Video “It Happened at Work”. Mick has worked very hard
on his own time in the evening to get the video completed. We still need to add introduction with Chad
and Resa, take out the Marathon clearance form and add credit to Marathon at the end of the video.
Donnie Watts mentioned it would be nice if there were lockers inside the plant for the guys to be able to
hang their jackets or tools in. Chad recommended building lockers in the C-van. Chad and Resa will
look into it while they are in the field on Thursday. Chad said he will check if Rodney Shull is over that.
Chad mentioned fatality incidents we need to see about getting a travel alarm or backup alarm for the
mini excavator 315. Resa said we can check with Jeff on getting a quote.
Next incentive handouts will be in June for Texas Hold’em. For all employees who participate, we will
hand out the extra t-shirts or hats that we have left over.
BEES Safety Committee -Budget for 2012 need to work on.
Meeting Adjourned at 8:00 a.m.
38
ATTACHMENT E - Monthly BEES Observation Reports
SENCO Employee BEES Individual Report (Participation)
Dates: 03/01/2012-03/31/2012
BBS Observations
Page 1
Type:
Individual Report
Observer: SENCO
All Observations
Observer Name Number of Observations Number Observed
Barrett Hill
8
12 Ben Inboden
2
4
Bill Sherman
22
58 Blake Wieland
27
52
Bob Pritts
22
39 Brad Dunlap
23
89
Brad Spinner
10
17 Brent Helm
10
11
Brian Rauch
4
11 Brian Leffler
5
15
Bryan Siler
20
35 Caleb Hartke
19
45
Carolyn Williams
14
28 Chad Brown
2
12
Chris Woods
24
70 Curt Reimer
8
12
Darrell Clark
21
71 Don Watts
25
74
Ethan Heuerman
22
64 Gail Kirkham
22
91
Greg Staley
3
4 Jaben Davis
22
60
James Webster
31
54 Jason France
30
90
Jeff Meehan
7
9 Jeff Boyd
3
3
Jim Wampler
24
46 Joe Dart
4
5
John Newlin
8
24 John Schnarre
22
43
John Smith
49
98 Justin Parker
2
3
Kent Walters
25
25 Kevin Boyer
17
38
Matt Lustig
21
55
39
Matt Miller
22
52 Matt Watts
10
26
Mike Connelly
22
85 Mike Briggs
18
33
Mike England
81
270 Mike Fulford
27
88
Mike Thoele
23
54 Monty Yockey
10
21
Neal Mellendorf
26
90
Paul Christman
1
2
Randal Brackett
23
85 Rick Harre
13
52
Roger Beucherie
22
53 Roger Creed
5
5
Scott Beard
9
33 Sheila Dawkins
20
55
Todd Wright
2
3 Wes Helm
21
68
William Flynn
25
49
Totals
953
2485
40
BEES Program Comments Report
Dates: 03/01/2012-03/31/2012
BBS Observations
Page 1
Type:
Observation Comments
Observer: SENCO
At Risk Observations
Observer Name
Date / Time
Workgroup Observed Comments
Gail Kirkham 3/1/2012 8:30 SENCO Picked up can of bolts, approximately 65lbs. told him
to put on pallet and use telehandler or use another
person to help carry
Tools / Equipment Safe At Risk Barrier
Transportation / Travel X Personal Choice
Brian Rauch 3/1/2012 11:00 SENCO cords for grinder under foot at workspace
PPE
Safe At Risk Barrier
Helper did not have on gloves and holding material in place for welder, did not put on for quick help. Put on after short
shot
Hand Protection
X Personal Choice
Work
Environment
Safe At Risk Barrier
Good team work and good communication Housekeeping X Business Systems
Darrell Clark 3/5/2012 8:30 SENCO
ground snowy and slippery, needed salt
Managing Weather Cond Icy
Safe At Risk Barrier
X Personal Choice Darrell Clark 3/6/2012 8:30 Brand said they didn't know if they
needed them in yard 7 PPE Safe At Risk Barrier Hearing Protection X Unsure of / Disagreement on Safe Practices Gail Kirkham 3/12/2012 11:00 SENCO employee had hard hat on
backwards, corrected PPE Safe At Risk Barrier Head Protection X Personal Choice Matt Miller 3/5/2012 14:00 SENCO Ladders were about to fall
over and some were on the ground. I learned them up so
they wouldn't fall or make tripping hazards
Tools / Equipment
Safe
At Risk Barrier
Scaffold, ladders & stairs ect
X Business Systems Storage
X Business Systems
Work Environment
Safe
At Risk Barrier
Tripping Hazards X Business Systems Bob Pritts 3/11/2012 14:00 Marathon
tied off to mid rail instead of vert. rail
PPE Safe At Risk Barrier PFAS X Personal Choice Jeff Boyd 3/15/2012 21:00 Other Carpenter started to get on
41
scaffold without harness; told him it was tagged for harness to be used. He climbed down.
No issues.
PPE Safe At Risk Barrier
PFAS X Personal Factors
Darrell Clark 3/15/2012 11:00 SENCO
forgot to put ear plugs in PPE Safe At Risk Barrier Hearing Protection X Personal Factors Randal Brackett 3/12/2012 8:30 SENCO
ask worker to use hard hat PPE Safe At Risk Barrier Head Protection X Personal Factors Matt Lustig 3/9/2012 10:00 SENCO working inside noise echoed a
lot, needed hearing protection
PPE Safe At Risk Barrier Hearing Protection
X Culture
Dates: 03/01/2012-03/31/2012
BBS Observations
Page 2
Type:
Observation Comments
Observer: SENCO
At Risk Observations
Observer Name
Date / Time
Workgroup Observed Comments
Matt Lustig 3/20/2012 10:30 SENCO worker was on floor for a few minutes before tying off,
should have tied off once he got on roof
PPE Safe At Risk Barrier
PFAS X Personal Choice Matt Lustig 3/20/2012 10:30 SENCO worked flipped up face shield
when it got day, said he couldn't see
PPE Safe At Risk Barrier
Face-Welding/Face Shield X Culture Matt Lustig 3/14/2012 10:30 SENCO good job for guys on roof
worker on ground cutting boards forgot earplugs
PPE Safe At Risk Barrier Hearing Protection X Culture Matt Lustig 3/19/2012 14:30 SENCO guys in tyvex suits were
working People Safe At Risk Barrier Pace X Culture
Matt Lustig 3/20/2012 8:30 SENCO work forgot ear plugs had them with him just forget to put them in before starting
saw
PPE Safe At Risk Barrier
Hearing Protection X Culture Matt Lustig 3/20/2012 9:30 SENCO worker forgot to put gloves
on after break/ when told, he put them on
PPE Safe At Risk Barrier Hand Protection X Culture Jaben Davis 3/21/2012 14:00 SENCO after high readings on
benzene meter the job was stopped until proper PPE was
determined
PPE Safe At Risk Barrier
Respiratory Protection X Unsure of / Disagreement on Safe Practices
42
Bob Pritts 3/16/2012 11:30 Senex confined space tight opening, hoses, cords in the way Work Environment Safe At Risk Barrier
Housekeeping X
Equipment / Facilities / Job Surroundings
William Flynn 3/20/2012 7:30
Veolia
needed shackles strapped them and had them get some
because hooks wouldn't fit lifting lugs
Tools / Equipment Safe At Risk Barrier
Proper Select / Use
X Personal Choice
Matt Miller 3/28/2012 10:30 Right Industrial Wood and other material
were in the way of the insulators they were stepping
on and over the material I told them to move it if it was in the way and they did good
job.
Tools / Equipment Safe At Risk Barrier Storage
X Personal Choice
Work Environment Safe At Risk Barrier Housekeeping
X Personal Choice
Tripping Hazards X Personal Choice
Bob Pritts 3/29/2012 9:30 Senex
overloaded bucket at risk People Safe At Risk Barrier Carrying / Moving
X Personal Choice
Pinch Points X Personal Choice
Ben Inboden 3/13/2012 8:00 Marathon There were cable cords and
welding leads strung everywhere. did very good job communicating and very good
safe and slow job
Work Environment Safe At Risk Barrier
Tripping Hazards X
Equipment / Facilities / Job Surroundings
Dates: 03/01/2012-03/31/2012
BBS Observations
Page 3
Type:
Observation Comments
Observer: SENCO
At Risk Observations
Observer Name
Date / Time
Workgroup Observed Comments
Ben Inboden 3/13/2012 13:30 SENCO pulling fuel hose up stairs is only way to fuel tank but I
took my time and got help to pull the hose up the stairs
Work Environment Safe At Risk Barrier
Tripping Hazards X
Equipment / Facilities / Job Surroundings
43
Attachment F - SENCO BEES Observation Point Summary Report
Dates: 03/01/2012-03/31/2012
BBS Observations
Type:
Observation Points Summary Observer: SENCO
Managing Weather Cond
# Safe % Safe # At Risk % At Risk
# Marked
% Marked
Icy
0 0.00% 1 100.00% 1 0.10% Windy
3 100.00% 0 0.00% 3 0.31%
3 75.00% 1 25.00% 4
People
# Safe % Safe
# At Risk % At Risk
# Marked
% Marked
Body Mechanics
914 100.00% 0 0.00% 914 95.41% Carrying / Moving
761 99.87% 1 0.13% 762 79.54%
Communication
791 100.00% 0 0.00% 791 82.57% Eyes on Task
905 100.00% 0 0.00% 905 94.47%
Handrail
99 100.00% 0 0.00% 99 10.33% Line of Fire
397 100.00% 0 0.00% 397 41.44%
Pace
750 99.87% 1 0.13% 751 78.39% Pinch Points
507 99.80% 1 0.20% 508 53.03%
5,124 99.94% 3 0.06% 5,127
PPE
# Safe % Safe
# At Risk % At Risk
# Marked
% Marked
Eyes- Safety Glasses/Goggles
914 100.00% 0 0.00% 914 95.41% Face-Welding/Face Shield
67 98.53% 1 1.47% 68 7.10%
Foot Protection
899 100.00% 0 0.00% 899 93.84% Hand Protection
907 99.78% 2 0.22% 909 94.89%
Head Protection
869 99.77% 2 0.23% 871 90.92% Hearing Protection
769 99.35% 5 0.65% 774 80.79%
Personal Monitor (H2S, SO2, etc.)
713 100.00% 0 0.00% 713 74.43% PFAS
36 92.31% 3 7.69% 39 4.07%
Protective Clothing
638 100.00% 0 0.00% 638 66.60% Respiratory Protection
52 98.11% 1 1.89% 53 5.53%
5,864 99.76% 14 0.24% 5,878
Procedures
# Safe % Safe
# At Risk % At Risk
# Marked
% Marked
Bypassing Safety Devices
7 100.00% 0 0.00% 7 0.73% Confined Space Entry
22 100.00% 0 0.00% 22 2.30%
Energy Isolation (LO/TO)
18 100.00% 0 0.00% 18 1.88% Hot Work
34 100.00% 0 0.00% 34 3.55%
Mat'l Handling / Storage
218 100.00% 0 0.00% 218 22.76% Safe Work Permit
599 100.00% 0 0.00% 599 62.53%
898 100.00% 0 0.00% 898
44
Tools / Equipment
# Safe % Safe # At Risk % At Risk
# Marked
% Marked
Barrier Tape/ Barricade’s
76 100.00% 0 0.00% 76 7.93% Condition
592 100.00% 0 0.00% 592 61.80%
Fall Protection
76 100.00% 0 0.00% 76 7.93% Guards
150 100.00% 0 0.00% 150 15.66%
Process Equipment
93 100.00% 0 0.00% 93 9.71% Proper Select / Use
579 99.83% 1 0.17% 580 60.54%
Scaffold, ladders & stairs ect
40 97.56% 1 2.44% 41 4.28% Storage
163 98.79% 2 1.21% 165 17.22%
Transportation / Travel
316 99.68% 1 0.32% 317 33.09%
2,085 99.76% 5 0.24% 2,090
Work Environment
# Safe % Safe
# At Risk % At Risk
# Marked
% Marked
Housekeeping
777 99.62% 3 0.38% 780 81.42%
Proper Lighting
444 100.00% 0 0.00% 444 46.35%
Tripping Hazards
161 97.58% 4 2.42% 165 17.22%
1,382 99.50% 7 0.50% 1,389
Grand Totals
15,356 99.81% 30 0.19% 15,386
45
Attachment G - SENCO BEES Coaching Guide
SENCO Facilitators Coaching Guide
Name of Coach_________ Date_________ In an effort to improve the overall quality of observations this guide was developed to help the various
BBSCAP facilitators critique their trained observers. This in turn will:
Help increase the quality of the observations being performed.
Drive more communication and proper specific feedback.
Positively motivate observers.
More facilitator and observer interface
One on one coaching.
Show the facilitator what they need to improve on or stress in their training programs.
Help improve the skills of the observers.
The coach should only take notes during the evaluation. Let the observer do the talking.
Introduction
Yes No
1. Observer asked permission to do observation.
2. Observer Explained the process.
3. Observer explained the feedback process
Feed Back
4. Observer discussed specific safe behaviors first.
5. Observer avoided using loaded words
6. Observer discussed specific At-risks seen.
7. Observer asked for commitment to working safe.
8. Observer kept discussion positive
9. Observer promoted discussion by asking questions.
10. Observer checked only the parts of the form that applied to the task.
11. Observer listened to answers, made sure employee understood.
12. Observer explained Is follow up needed
General
13. Observer legibly filled out all applicable portions of the form
14. Observer filled out comment section of form
15. Observer treated worker like the worker wanted to be treated.(Platinum)
16. Upon completion observer showed employee finished form
Comment
Note a QUALITY observation is;
A Quality Observation is Clearly Written
A Quality Observation has All Information Filled in
A Quality Observation Includes Communication with the Person being Observed
A Quality Observation that indicates an at Risk Situation, include a Barrier and Explain the Unsafe Act
A Quality Observation is Turned in in a Timely Manner
