“beginning in 1999 [john] mathis and others at cii began ... · “beginning in 1999 [john]...
TRANSCRIPT
1
“Beginning in 1999 [John] Mathis and others at CII began taking detailed looks at 38 projects with construction values of
$50 million to $600 million. They found the fewest accidents on projects where top management insisted on listing safety
training as a budget item, participated in investigations ofrecordable injuries and encouraged anonymous disclosures of unsafe behaviors. On the safest projects, every worker on site received at least four hours per month of safety training, each safety professional served no more than 50 workers and
subcontractors submitted site-specific safety plans. Mathis urged wider adoption of such safety practices, in an industry
in which work-related accidents kill approximately 1,000 construction workers annually.”
– David B. Rosenbaum, Craft Labor Shortage Provokes More Studies of Pay and Safety, ENR,
August 20, 2001
2
CII: Making
Zero Accidents
a Reality
John Mathis
3
“CII: Making Zero Accidentsa Reality”
! Construction Industry Institute (CII)
! Take a safety journey! Review the research methodology
! Reveal best practices identified ! Review and discuss key findings
! Summary and questions
4
Project Team160 - Committee Members
Bill AlferaFPL Energy, Inc.
Alan R. BurtonCianbro Corporation
Mike CainLockwood Greene
Dennis CobbE.I. du Pont de Nemours & Co., Inc.
Pual DeForgeOntario Power Generation
John A. GambateseOregon State University
Tom hardestyCelanese Acetate
Jimmie W. HinzeUniversity of Florida
Scott JohnsonTyco/Grinnel Fire Protection
Randy MarconnetWatkins Engineering & Constructors, Inc,
Bill W. PoppellFlorida Power & Light Company
Mike F. SchwimmerChevron U.S.A., Inc.
Gary L. WilsonNCCER
P.D. FreyAustin Industries
5
Construction Industry Institute
A consortium of leading owners,
contractors, suppliers, and academia
who are interested in improving the
constructed project and the capital
investment process.
6
CII Mission
To improve the safety, quality,
schedule, and cost effectiveness of its
members through research and
implementation support for the purpose
of providing a competitive advantage to
its members in the global marketplace.
7
Owner Members
!Exxon!Chevron!Shell!BP/Amoco!Dupont!Conoco!Citgo!Texaco!Phillips
!Celanese!Intel!General Motors!Alcoa!Reliant Energy!Nasa!TVA!Ontario Power!U.S. Steel
8
! Foster Wheeler USA
! Jacobs Engineering
! Kellogg Brown & Root
! Kiewit Construction
! Morrison Knudsen
! H. B. Zachry
! Stone & Webster Engineering
! S&B Engineers and Constructors
! ABB Lummus Global
! Bechtel Group
! BE&K
! Black & Veatch
! Chicago Bridge & Iron
! Burns and Roe
! The Parsons Corp.
! Rust Contractors
! Fluor Daniel
CII Contractor Members
9
! Kentucky
! Lehigh
! MIT
! New Mexico
! North Carolina State
! North Dakota State
! Oklahoma State
! Oregon State
! Penn State
! Polytechnic University NY
! Purdue
! Stanford
! SUNY-Buffalo
! Arizona State
! Auburn
! Cal-Berkeley
! Carnegie Mellon
! Cincinnati
! Clemson
! Colorado
! Columbia
! Drexel
! Florida
! Georgia Tech
! Houston
! Illinois
! Iowa State
Participating Universities
! Texas
! Texas A&M
! Virginia Tech
! Washington
! Wisconsin
! Worcester Polytechnic
! Xavier
10
CII Knowledge Structure
Identifies CII:
! Best Practices! Pending Best Practices
! Informational productsIndustry input critical to Best Practice selection.
All Best Practices validated.
11
First CII Zero AccidentsStudy 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
12
CII Lost Work CasePerformance - 1993-1999
3.674
4.44.54.9
5.55.5
0.270.410.310.450.550.81
0.63
0
1
2
3
4
5
6
1993 1994 1995 1996 1997 1998 1999
Indus try *C II
Lo
st W
ork
day
Cas
e In
cid
ence
Rat
e
Year and Work-hours (MM) * OSHA SIC 15
LWCIR FOR AGGREGATED DATA
Est.
13
12.2 11.810.6
9.9 9.58.8
8.21
3.44 3 2.66 2.31.6 1.59 1.67
0
2
4
6
8
10
12
14
1993 1994 1995 1996 1997 1998 1999
Industry*CII
CII OSHA RecordablePerformance - 1993-1999
Rec
ord
able
Inci
den
ce R
ate
Year and Work-hours (MM) * OSHA SIC 15
RIR FOR AGGREGATED DATA
Est.
14
Zero Accidents - Revisited
What safety best practices have supported this improvement and are at the forefront of safety management today?
“Making Zero Accidents a Reality”Nov. 1999
Project Team -160
15
Zero Accidents Study 2000/2001
Methodology – two studies" Large construction firms
" Large construction projects
Survey of 400 largest construction firms in the U.S.
" Based on ENR 400 for 1999
" 400 surveys sent – 102 responses
16
Zero Accidents Study2000/2001
Detailed interviews on construction projects" 38 Projects" Types
! Petrochemical! Industrial! Public works! Transportation! Hotel-Casino! Commercial buildings
" Locations: U.S. wide geographic area" Sizes: $50-$600 million
17
Nine Zero Accident Best Practices
! Demonstrated management commitment! Staffing for safety ! Safety planning! Safety training and education! Worker participation and involvement! Subcontractor management! Recognition and rewards! Accident/Incident reporting and
investigations! Drug and alcohol testing
18
Best Practice Results
Over 30 key findings revealed significant lower recordable injury rates with companies utilizing these best practices.
19
Demonstrated Management Commitment
! Safety mission statements! Project-specific newsletters! Top Management involved in
accident/incident investigations of recordable and lost time injuries
! Top Management personally involved in reviewing safety performance reports
! Senior field management" Participation in field safety
inspections" Participation in orientation
20
Demonstrated Management Commitment
Top management participated in investigation of recordable injuries
0
1
2
3
4
5
6
7
Every Injury 50% or Less
RIR
21
0
1
2
34
5
6
7
8
9
Every Injury 50% or Less
RIR
Demonstrated Management Commitment
Top management participated in investigation of lost time injuries
22
0
1
2
3
4
5
6
7
Yes No
RIR
Demonstrated Management Commitment
Company president/senior management reviews safety performance report
23
Demonstrated Management Commitment
Home office safety inspections on the project
0
0.5
1
1.5
2
2.5
3
W k/B i-W k O th er
R IR
24
Demonstrated Management Commitment
Corporate accident report summary provided to all the jobs?
0
0.5
1
1.5
2
2.5
Yes No
RIR
25
Safety Staffing
People, methods, resources, and key impacts
! Adequate staffing
! Safety involved in project meetings
! Safety included in cost,scheduling, and quality reports
26
Safety Staffing
Safety professionals per 50 workers
0
0.5
1
1.5
2
2.5
Up to 50 Over 50
RIR
27
Safety Staffing
View of safety personnel by other workers on the site
0
1
2
3
4
5
6
7
8
Positive Negative
RIR
28
Safety Staffing
Who does the safety representative report to?
0
0.5
1
1.5
2
2.5
Corparate/staff Line/Project
RIR
29
Safety Planning
Pre-project and pre-task planning-key impacts
! Job hazard analysis! Constructability reviews
! Pre-task planning! Site-specific safety programs
30
Safety Planning
Does the project have a site-specific safety program?
0
1
2
3
4
5
6
Yes No
RIR
31
Safety Planning
Pre-task meetings held?
0
0.5
1
1.5
2
2.5
3
Yes No
RIR
32
Safety Training and Education
! New worker safety orientation
! Follow-up safety training! Tool box safety meetings
33
0
0.5
1
1.5
2
2.5
3
Yes No
RIR
Safety Training and Education
Is Safety Training a line item within the budget?
34
0
0.5
1
1.5
2
2.5
3
3.5
4
Formal Informal
RIR
Safety Training and Education
Every Worker on site receive a formal standard orientation
35
0
0.5
1
1.5
2
2.5
3
3.5
4
Up to 4 hrs Over 4 hrs
RIR
Safety Training and Education
Additional monthly training for employees
36
Safety Training and Education
What day toolbox safety meetings held
0
0.5
1
1.5
2
2.5
3
3.5
M onday Tuesday-Thursday
Varies
RIR
37
Worker Involvement and Participation
! Employee/Involvement Safety Teams
! Worker-to-worker observation process
! Worker perception surveys
38
Worker Involvement and Participation
Are safety observers used on the projects?
0
1
2
3
4
5
6
7
8
Yes No
RIR
39
0
0.5
1
1.5
2
2.5
3
Yes No
RIR
Worker Involvement and Participation
Workers trained and utilized for worker-to-worker observation?
40
Worker Involvement and Participation
Do management and supervisory personnel receive behavior overview training?
0
0.5
1
1.5
2
2.5
3
Yes No
RIR
41
Worker Involvement and Participation
Total amount of safety observation reports filed on the project
0
0.5
1
1.5
2
Up to 100 More than 100
RIR
42
Worker Involvement and Participation
Are safety perception surveys conducted on the project?
0
0.5
1
1.5
2
2.5
3
Yes No
RIR
43
Recognition and Rewards
Effect of worker safety incentives
! Individual versus crew incentives! Based on injuries or safe behavior
! Frequency of awards! Career progression
44
0
0.5
1
1.5
2
2.5
3
3.5
Yes No
RIR
Recognition and Rewards
Does a formal worker incentive/ recognition and reward program exist?
45
0
0.5
1
1.5
2
2.5
3
3.5
Wk/Bi-Wk Quarterly
RIR
Recognition and Rewards
How often are incentives given to workers?
46
Recognition and Rewards
Incentive based on zero injury objective?
0
0.5
1
1.5
2
2.5
3
3.5
Yes No
RIR
47
0
0.5
1
1.5
2
2.5
Yes No
RI R
Drug and Alcohol Testing
Do family members attend safety dinners?
48
Recognition and Rewards
Field supervisors evaluated on safety?
0123456789
Yes No
RIR
49
Subcontractor Management
!Site-specific safety plans
!Site orientation!Sanctions for sub-standard
performance!Frequency of safety meetings
50
0
0.5
1
1.5
2
2.5
3
3.5
4
Yes No
RIR
Subcontractor Management
Subs submit site-specific safety plans?
51
0
1
2
3
4
5
6
Yes No
RIR
Subcontractor Management
Subs attend a formal standard safety orientation?
52
0
1
2
3
4
5
6
YES NO
RIR
Subcontractor Management
Sanctions are imposed for non-compliance?
53
Subcontractor Management
Frequency that subs hold safety meetings
0
0.5
1
1.5
2
2.5
Daily Weekly
RIR
54
Accident/Incident Reportingand Investigation
! Documented near misses
! Top management involvement
55
Accident /Incident Reporting and Investigation
Amount of near misses recorded on the project
0
0.5
1
1.5
2
2.5
Up to 50 More than 50
RIR
56
0
1
2
3
4
5
6
Every Injury 50% or Less
RIR
Accident/Incident Reporting and Investigation
Recordable injuries investigated by top management
57
Work in Progress
! Implementation Data Sheets
! Education Modules! Outage/Turnaround Research
! Overtime Research
58
Best Practices
Getting to Zero Accidents! Demonstrated management
commitment ! Staffing for safety! Safety planning – pre-project/pre-task! Safety training and education! Worker involvement and participation! Recognition and rewards! Subcontractor management! Accident/incident reporting and
investigation! Drug and alcohol testing
59
Types of Contract
Is Safety managed as a value?
0
0.5
1
1.5
2
2.5
Lu m p Su m C ost P lu s
R IR
60
Concluding Remarks
! Establish a Formal Safety Education Process for management, and the workers
! Evaluate and measure the safety management system
! Reward management, workers, and subcontractors for safe behavior
! Make safety a evaluation criteria for Management and supervision
! Engage sub-standard safety management, practices & conditions at all levels
61
Concluding Remarks
! Demonstrated management commitment is essential
! Employee involvement is essential
! Integrate safety early into the project development and planning process
! Build your project safety plans based on specific scope and risk;
! Pre-Task analysis is critical
62
Even if you’re on the right track,you’ll get run over if you just sit there.
Will Rogers