Innovations In Safety

A Leadership Perspective

Anand Sen

President, Tata Steel

A Leadership Perspective

The Hindenburg

catastrophe,

May 6, 1937

The Halifax explosion, December 6, 1917

Fukushima, Japan

High Impacting World Events

1984

The Union Carbide

Gas Leak

15000 killedPiper Alpha

The fate of USS Shaw, December 7, 1941

1986 Chernobyl Disaster

Fukushima, Japan

Earthquake and Tsunami (2011)

795524628

3793

40000

Work Place Fatalities (2011- 2012)

374

40000

Source : Internet

On Road Fatalities (2013)

Road Traffic Death Rates Per 100 000 Population

Road fatalities worldwide estimated at 1 million

every year – more than people dying of

tuberculosis and malaria

Source:Economist

Region Wise Fatalities In Steel Industry (2004-2012)

142

187

219

220

Moving Machinery

Heavy vehicles and Mobile equipments

(Rail & Road)

Loss of Containment

Fall from Height /fall objects

Hazard Wise Fatalities In Steel Industry (2006-2012)

18

33

48

0 100 200 300

Structural Failure

Prod. Handling / Storage/ loading

Overhead Crane

Most Safety Critical Activities

in Steel Industries

• Fall from Height

• Loss of containment

• Vehicular Safety

• Moving Machinery

Source : World Steel Association

Leadership ChallengesLeadership Challenges

Evolution of Leadership Culture

Interdependent leadership culture

view leadership as a collective

activity that requires mutual

inquiry, learning and a capacity toinquiry, learning and a capacity to

work with complex challenges

Independent leadership

Cultures assume that leadership

emerges as needed from a variety of

individuals based on knowledge and

expertise

Dependent leadership

Cultures hold only people in

position of authority

responsible for leadership

Safety Culture

Process Safety Management

Bradley Curve

11Source : DuPont

“I follow the rules because I have to” “I follow the rules because I want to”

Culture Bridge

We Must Cross Culture Bridge

12

Source : DuPont

Transform to

Steel Chemical Nuclear Aircraft

Safety by

Culture Management

Cultural Evolution

Management

Accountability

• Safety integrated

business

• Felt leadership

• Consequence

Management

• Risk Based

Approach

• Operational

Discipline

• Personalise

Value

Hazard

Analysis &

Risk Mitigation

• Process Safety

Management

• Operational Risk

Management

• HAZOP.

• Lockout Tag out

Regulatory

Compliance

• Behaviour

Based Safety

• Personal

Protective

Equipments

• Situational Awareness

• Zero Tolerance

• Culture Valuation

• Strong response to weak

signals of heightened

risk

• Cognitive decision

making

• Social responsiveness

• Challenge Safety Critical

Decisions

Risk Based Approach

Highest Most

Bow-tie : Smart Tool To Manage Process Incidents

Tata Steel StoryTata Steel Story

Overview Of Tata Steel A Global Steel Major

Tata Steel Group

Tata Steel India

Nat SteelTata Steel

Thailand

Tata Steel

Europe

Product Segments

Uniquely positioned steel maker present in developed and developing markets across a wide range

of segments

PlanPlanCheckCheck

ActStep Change

ActStep Change

1) Apex Safety Council

Chairman: MD India and South East Asia

Policy Development, Facilitating & Review Safety

Committee

3) Apex Safety Sub Committees (6)

Chairman: Vice President

2) Safety Excellence Journey Review

Chairman: President TQM & Steel Business

Safety Governance Structure

Policy

Management

PlanPlan

DoDo

CheckCheck

qqqq1

Divisional Implementation Committee

Chairman: Vice President

Area Implementation

Committee

(Employees)

Chairman: Chief of Dept

Policy Deployment Safety Committees

Area Implementation

Committee(Contractors)

Chairman: Contractor

Partner

Daily

Management

Injuries Prevention Process Incidents Prevention

Safety Management System & Risk Management Matrix

Operational

Discipline

Safety Management

Elements of Behavioral Safety Elements of Process Safety

LEADERSHIPOPERATIO

NAL

ORGANISATIO

NALTECHNOLOGY PERSONNELFACILITIES

OSHMS (Occupational Safety and Health Management System) :

An Integrated Approach

Involvement of safety Passionate and union representatives

Barrier Failure Analysis

Case Of Gas Holder Explosion

Automatic Operation

Manual Remote Operation

Manual Local Operation

Manual Mechanical Operation

1

2

3

4

• Controls for five above (B2-B6) were routed through Gas Recovery

PLC (ML01). PLC was failed.

• Barriers B1 and B8 are controlled through ID Fan and Gas Holder

PLCs, respectively. Barrier B7 is operated manually.

• Barrier B1 was not activated.

• Barrier B8 was not exercised and B7 was under the process of

activation

GPS System in Bus &

Loco Engines

Technology in Safety

SOP

Online

monitoring

system

on mobiles

Automation in track change

operation by motorized point

CCTV camera to

observe the unsafe

act on road

Maturity Reporting Of Safety Performance

Reactive Fatal

Serious

Incidents

Near

Misses

Proactive

Unsafe

Conditions

Unsafe acts

Audits &

ReviewsPreventive

Safety Collage

Achievements

� 90 Safety standards developed & facilitated for

implementation .

� 100% ban of two wheelers inside works for non critical

activities.

� 3 mtpa brown field expansion without any incident.

� Exclusive safety & health institute for contract employees.

Awards & Applauds

� Exclusive safety & health institute for contract employees.

Awards

�World Steel Association “Excellence Recognition”

2009 : Construction Safety-

2010 : Confined Space Management

2011 Safety and Health

2012 : Cultural transformation at construction sites

� 1. CII Eastern Region SHE Award -2011

�2. CII – Eastern Region SHE Award – 2012

�3. Zonal Mines Rescue Competition FY’12

�4. Odisha Metallic Ferrous Mines Safety Competition

�5. 2010,2011 Ispat Suraksha Puraskar by Joint Committee

TSL – India OperationsWay Forward

Effectiveness

Increases

As Incidents

Decrease….

Thanks

Backup SlidesBackup Slides

Safety

Management

System & Risk

Management

Matrix

Co

nse

qu

en

ce

Implement Process safety No Future here !

Low Frequency

Frequency Consequence

- Process Incident

High Frequency

High ConsequenceHig

h

Approach to Manage Risk for Injuries and process Incident

(Risk= Frequency X Consequences)

Safety Aspiration

Co

nse

qu

en

ce

Frequency

Implement Process safety

management

Low Frequency

Low Consequence

Implement

Behaviour safety“The Goal is Zero”

High Frequency

Low Consequence

- Injuries due to Unsafe act

Low

Low High