senco construction inc. application for the … · 25 trend/pattern analysis hazard...
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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.
2015
“Safe by Choice Leading By Example
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INDEX
Page Content
1 Application Cover Sheet
2, 3 Application Index
4 Company Information/Services
5 SENCO Safety Achievements, Community Involvement
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
10 Trend Injury Information
10 Trend SENCO Safety Statistics
11 Trend First Aids v Observations, Incident Rate vs. BEES
Observation
11 Trend Observations to First Aids to BLS Rates
12 SENCO Injury Man/Injury Descriptions 2012
13 SENCO Injury Man/Injury Descriptions 2013
14 SENCO Injury Man/Injury Descriptions 2014
15 BEES Overview SENCO BEES Program Overview/Belief’s/Data 6 Years
16 Significant Changes or Events
17 Significant Changes or Events Cont.
Management/Leadership and Employee
Involvement
18 Goals, Objectives and Planning
19, 20 Visible Top Management
Responsibility and Authority
Line Accountability
Employee Involvement
20, 21 Employee Involvement Cont. Superintendents and
Foreman Responsibilities
22 BBS/BEES Training Program
23 SENCO BEES Steering Committee
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Written Safety and Health Management System
Work Site Analysis
24 Routine Self Inspections
Hazard Reporting Systems for Employees
Industrial Hygiene Program
Investigation of Incident and Near Misses
25 Trend/Pattern Analysis
Hazard Prevention/Control
25 Hazard Prevention Control Cont.
Success Stories
26 Success Stories Cont.
Certification Signatures for Application
Page Description of Attachment
27, 28 Attachment A – SENCO Texas Hold’em Card Game Rules
29 Attachment B– SENCO Texas Hold’em Card Game Tracking Sheet
30 Attachment C – Sample BEES Steering Committee Meeting Notes
31, 32, 33 Attachment D – Monthly BEES Observation Report (Participation)
34, 35 Attachment E – SENCO BEES Observation Point Summary Report
36 Attachment F – SENCO Bees Coaching Guide
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COMPANY Information
SENCO CONSTRUCTION INC. is a privately held Illinois corporation owned by Chad and
Michele Brown of Robinson, Illinois. During the past 3 years under Mr. and Mrs. Brown’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.
SERVICES
SENCO CONSTRUCTION offers a broad line of services for new construction and plant
maintenance, including site work, concrete installation, structural steel erection, heavy lifting and
rigging, 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-site equipment maintenance to ensure safety
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 Health
and Safety Director and 3 Safety Technicians. SENCO Construction’s Safety Department
continues to grow as the work grows.
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, 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 welding inspection service.
SENCO CONSTRUCTION provides all manpower and equipment necessary to crush and size
coke from Marathon Petroleum Company’s Coker Unit. SENCO’s coke crushing operations are
performed daily, including, minimum of 23,000 tons processed monthly.
SENCO CONSTRUCTION is an EPA First Response equipment and manpower provider for the
Illinois Refining Division.
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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 April 2015.
Marathon Contractor Safety Excellence Award – SENCO has received the Marathon
Contractor Safety Excellence Award 7 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.
NCCCO Accreditation
Community Involvement
2010 Performed Observation Training to the Robinson High School for the senior class,
performed walk thru of their wood shop and Mechanical shop to identify hazards and teach them
to help keep their work areas safe.
2013/2014 Career Day for local students to meet with union representatives and performed hands
on training.
Striving for a safe work place for all employees, manage the BEES observation program in a
proactive manner to help improve safety culture.
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DESCRIPTION OF WORKFORCE
SENCO Employees:
SENCO currently employs 148 union and supervision employees including 30 SENCO
Company employees.
Age: The average age for SENCO employees is 42.5 years..
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 7 different unions.
SENCO BEES Data Types (Reports) BBS Reports: SENCO uses the Marathon ACTS data base to input data and build reports
through a website with password protection. 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.
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.
Lost Time Incident Rate: This rate is also tracked annually.
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
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appropriate body parts was introduced. This visually showed that the majority of injuries are
hand injuries in the past, which led to the formation of the Hand Protection annual compliance
training topic and glove program, since that time hand injuries have decreased significantly.
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 on SENCO’s worksites. 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 day’s work as safely as possible.
SENCO observers are encouraged to use the SENCO Coaching Guide (Attachment F) to help
fellow employees become acclimated to performing observations; SENCO added the use of
coaching guides in the SENCO Texas Hold’em Card game. See the game rules in Attachment A
See Attachment F – 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. Let them know you will discuss the observation and the data sheet with them.
5. Stick to the subject at hand – stay focused.
6. Be positive, smile, make eye contact, and be confident.
7. 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.
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Injury and Illness Data
Injury & Illness Rate Information
Site Name: SENCO Construction
Calendar Year
Date Submitted
2015
July 2015
Corporate Information
Name/Address SENCO Construction
1408 S Eaton
Robinson Ill 62454
Phone: 618-546-1485
Site Information
Address SAME
Phone: SAME
Company Owner(s)
Chad Brown
Michele Brown
Site VPP Contact
Chad Brown- Co-Owner
Michele Brown- Co-Owner
Nick Martin- Health and Safety Director
NAICS / SIC
237120/237
FAX
VPP Status
618-546-1120
STAR
# Applicable Union
Contractors*
# Site Employees*
Total
Total Hours Worked
7
163
SAME
285,098
Site Injury & Illness Rate**
(2014)
TCIR: 0.70
DART: 0.00
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Graphs
The data shown above was gathered to show our employees that when the number of
observations performed goes down, the number of incidents go up. On the same graph we
illustrated that when the number of observations go up, the number of incidents go down.
0
1
2
3
4
5
6
7
8
0
100
200
300
400
500
600
700
800
900
July August September October November
# of Observations compared to Incidents
Observations
Incidents
Table B-1
VPP Participant’s Recordable Non-Fatal Injury and Illness Case Incidence Rates
1
2
3
4
5
6
7
Year
Total
Number
Employees
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)
2014 163 285,098
1
0.70
0
0
Most recent published BLS rate for NAICS
code 237120
1.4
.4
Percent above or below National Average
50% Below
100%
Below
10
0
0.2
0.4
0.6
0.8
1
1.2
1.4
EMR TRIR DART
2012
2013
2014
0
2
4
6
8
10
12
2012 2013 2014
Injury and Illness Information Compared to Observations
First Aids
Recordables
Observation's divided by 1,000
Injury and Illness Rate Information
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0
2
4
6
8
10
12
2012 2013 2014
First Aids vs. # of Observations
First Aids
Observation's divided by1,000
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2012 Incident Data
First Aid Injury 2012 OSHA Rec
1 Abrasions 2 Contusions
1 Crushing Injury 3 Foreign Body
General Medical
1 Laceration Puncture
Wound
2 Strain Sprain
1 Allergic Reaction
Thermal Burn Flame Burn
Dislocation
Fracture Heat
8 Total Injury Types
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Totals
0
13
2013 Incident Data
First Aid Injury 2013 OSHA Rec Abrasions
Contusions 1
Crushing Injury Foreign Body
General Medical 2 Laceration
Puncture Wound
Strain Sprain
1 Insect Bite Thermal Burn
Flame Burn Dislocation
Fracture Heat
2 Total Injury Types
1
3
Totals
1
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2014 Incident Data
First Aid Injury 2014 OSHA Rec Abrasions
Contusions 1 Crushing Injury
Foreign Body
General Medical 1 Laceration 1
Puncture Wound
2 Strain Sprain Insect Bite
Thermal Burn Flame Burn
Dislocation
Fracture Heat
3 Total Injury Types
1
4
Totals
1
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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 on SENCO Construction worksites. 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 BEES 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 2 observations each work day.
SENCO BEES 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 BEES 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".
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
2012 7495 150 244 3% 23 174,851
2013 4598 88 208 5% 37 168,408
2014 8685 167 528 6% 33 285,098
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Significant Changes or Events
1. SENCO BEES Observation Improvement Plan 2015 SENCO’s Behavioral Based Safety
Steering Committee developed a BEES (Behaviors Encouraging Employee Safety)
Improvement plan for 2014. After reviewing observation data from 2014 it was concluded that
an opportunity for improvement was to create our own observation form. The SENCO Steering
Committee met on three different occasions to develop the new form.
In the 2015 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.
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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. SENCO has maintained its incentive
program and continues to see an increase in participation.
*SEE Attachment A 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. 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 is
performed annually by SENCO to ensure all employees understand and can take part in the
PTHA process. These PTHA’s are also audited monthly to ensure they are being completed for
every job.
4. BEES Steering Committee The BEES meets bi-weekly and is comprised of 8 hourly
employees. This year the steering committee’s knowledge was used in developing the new
observation pads. The observation pads are tailored to SENCO’s work scopes and will be
reviewed at the end of the year with the steering committee. One goal of the steering
committee this year was to obtain involvement from MPC at our bi-weekly meetings. MPC
project coordinators have been in attendance throughout the year.
Management Leadership and Employee Involvement
Management Commitment to Safety/Health Protection and to the SENCO Observation
Program
SENCO management is in complete support of 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 shows 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
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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 Monday mornings for 30 minutes after our safety meeting.
The SENCO safety department will provide observer training to all employees, and 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 MPC, and help promote the Observation program on all SENCO jobs.
Employees are asked to perform at least 2 observations per day. SENCO also has two BEES
Blitz’s a week; this is when the employees flood the observation data base with observations.
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 put
them in the BEES drop box, the observations then go to the SENCO receptionist to have the data
entered into the database.
Policy
SENCO Management and Safety Department have developed the SENCO BEES Observation
Program Policy SSP-58, it details program requirements and goals.
Goals, Objectives, and Planning
SENCO goals for 2014 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. Goals for
2015 include.
Create new observation form.
100% of workforce trained.
Include MPC representatives in bi-weekly steering committee meetings.
Hours between observations at 25 or below.
Re-emphasize BEES Blitz (twice a week).
Get more Superintendent Involvement.
Maintain BEES Newsletter.
Maintain Rewards Program.
*Attachment C for recent BEES steering committee meeting notes
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Visible Top Management Leadership
SENCO Management and Safety Department ensure that all employees are actively involved in
SENCO BEES Observation program by allowing SENCO employees to be a 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.
Employee Involvement
In 2015, 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.
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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.
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, 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.
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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. 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
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
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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
Written Safety and Health Management System
A Safety Improvement internal assessment program has been implemented and used for all Safety and
Health programs; the latest being completed in January 2015 for the 2015 year. These assessment results
will be placed into a summary document. This summary allows each deficiency to be documented and the
Health and Safety Director then develops an action plan to track issues to completion. A monthly review
of progress is reported to the SENCO management team.
Worksite Analysis
Hazard Analysis of Routine Jobs, Tasks, and Processes
Our PTHA (Pre Task Hazard Analysis) is a tool on all SENCO jobs. SENCO employees are required
to use these PTHA’s before any job or task is started. 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.
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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. SENCO continues to perform Targeted Assessments.
Quarterly Facility Safety Audits are performed on all five SENCO sites, action plans are built for the
issues noted on the facility audits for tracking to completion. We also complete Daily Jobsite Audits
and Weekly Housekeeping audits. The goal in 2015 is to continue to complete all regulatory
inspections along with SENCO’s auditing process.
Hazard Reporting System for Employees
Safety Suggestions, Employee Safety meetings, BEES Observations, Daily Job Safety Reviews,
PTHA’s, Bi-weekly Contractor Safety meetings, STEPs safety meetings, and Quarterly Contractor
Safety Meetings (all are attended by the SENCO Safety Department). Safety Suggestions and Safety
Opportunities Shared (SOS) are some methods used to initiate corrective measures.
Industrial Hygiene Program
SENCO Construction has built a detailed Industrial Hygiene Monitoring Program. SENCO uses our
Insurance provider to perform the testing and analyze the results. With the assistance of 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 the following:
Noise Exposure
Welding Vapors (Heavy Metals)
Respirable Dust
Mercury
Poly Nuclear Aromatic Hydrocarbons/Benzene Soluble
Benzene/Voc’s
Carbon Monoxide
Silica
SENCO completed annual audiograms for employees that have the possibility to be 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
2014.
25
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.
Investigation of Incidents and Near Misses
The SENCO Incident 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.
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 is continuously being
updated. Trending through Injuries, Observations and employee input helps us to determine what
needs to be changed or improved with the PPE.
Preventive/Predictive Maintenance
The SENCO Maintenance Department performs Preventative and Predictive Maintenance on all of our
own heavy equipment as scheduled, maintenance reports are kept at the SENCO shop. We are
currently performing fall protection, rigging, ladder, and fire extinguisher inspection for 2015.
26
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 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 up to 30 minutes in duration.
SENCO employees are also required to complete specialized training for certain tasks, such as; Fork
Lift, Crane/Picker, AWP, PIV, HAZWOPER 40 Hour, HAZWOPER 8 Hour, Signal Person Training,
Rigging, BEES observations and all required safety policies.
Emergencies
All employees are trained on SENCO’s emergency evacuation policy. Plant Evacuation Drills are held
annually with a critique 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 to the plant. They adhere to all SENCO safety policies and procedures and get
pre-approved to perform work in the facility.
Success Story
Safety culture of SENCO employees; SENCO employees have continued to show an improvement in
safety culture. Employees are encouraged to ask questions. Employees complete and discuss PTHA’s
on a daily basis during the morning toolbox talk. Employees complete and use daily prestart checklist
to ensure equipment is safe for operation.
SENCO Construction continues to push every aspect of Behavioral Based Safety. Goals have been
developed for the 2015 year to increase supervisor participation, raise employee participation, and
invite MPC employees to SENCO steering committee meetings to get new ideas.
27
Attachment A - 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 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 $FR Carhart Shirt, 2
nd and 3
rd will be gift
certificates
28
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
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.
29
Attachment B - 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
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♥
♠
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
♣ ♦
30
Attachment C - Sample BEES Steering Committee Meeting Notes
BEES Steering Committee Meeting
March 30, 2015
In Attendance: Nick Martin, Michele Brown, Brian Bricker, Josh Bass, Tom Huss, Chad
Swalls, Randy Brackett and Mandy Hale.
Special Task’s for the SENCO BEES Steering Committee:
Short Shot form revisions
100% of work force trained in the BBS Process
Include MPC Representative(s) in our BEES Program Steering Committee
Hours between observations need to be at 25 or below
Reemphasize BEES Blitz-2 BEES Blitz’s a week
Get Superintendent Involvement
Rewards Program-Monthly and Quarterly
Monthly Safety Newsletter
Meeting Notes:
New BBS Observation book-everyone seems to like it because it pertains to their work.
More efficient because the book is tailored toward their work.
Nick mentioned maybe creating books for Senex that pertains to work they perform.
Under PPE, there are two categories for eyeglasses and protective eye wear. We need to
remove one of them from the observation booklet.
The numbers stayed the same.
Need to make sure all superintendents are on board. A lot pertains to the amount of effort
and time management.
Randy mentioned the leading edge jobs since we have a lot of augers, caissons etc. Don
has done a good job of explaining to the guys.
Nick mentioned to continue to raise awareness for pinch points.
31
ATTACHMENT D - Monthly BEES Observation Reports
SENCO Employee BEES Individual Report (Participation)
Dates: 01/01/2015-02/01/2015
BBS Observations
Page 1
Type:
Individual Report Observer: SENCO
All Observations
Observer Name Number of Observations Number Observed Blake Davidson
8
21
Bob Pritts
4
10
Brad Reinbold
24
36
Brad Spinner
5
8
Brandon Higgins
14
42
Brent Helm
2
3
Brian Bricker
24
60
Brian Leffler
2
6
Brice Padgett
1
1
Butch Chambers
10
36
Calvin Murray
8
13
Chad Charley
1
2
Chris Stifle
18
46
Chris Woods
1
1
Dan Holton
8
32
Darrell Clark
4
8
Derek Malone
11
19
Don Bousley
17
43
Eric Adamski
20
103
Eric Polston
22
64
Gail Kirkham
40
162
Gary Simonton
2
6
Gary Watts
15
17
Geraldd Dowd
8
10
Gregg Sapp
10
37
Jaben Davis
2
7
James Richardson
26
56
James Webster
21
40
Jared Veach
8
13
Jeff Boyd
1
1
Jeff Vahling
2
6
32
Jim Wampler
19
38
Joe Dart
9
13
Joey Akers
19
22
John Bray
3
12
Josh Bass
21
35
Kenny Valle
7
18
Kent Walters
10
16
Kevin Boyer
21
50
Kevin Cooper
3
8
Luke Bickers
2
6
Mary Gallant
7
14
Matt Miller
22
51
Michael Davidson II
13
19
Michael Schmidt
32
64
Mike England
90
417
Dates: 01/01/2015-02/01/2015
BBS Observations
Page 2
Type:
Individual Report Observer: SENCO
All Observations
Observer Name Number of Observations Number Observed Monty Yockey
3
5
Neal Mellendorf
19
58
Nick Martin
9
31
Paul Christman
19 29
Paul Keltz
4
15
Randal Brackett
21 56
Ray McCammon
13 24
Rhett Brown
5 10
Rick Wahl
1 1
Robert Goff
1 1
Robin Higginbotham
18
47
Roger Creed
3 3
Rory Knearem
9 15
Roxanna Cantrell
4
9
Russ Rehmel
12 38
Scott Beard
8 16
Shawn Hetzler
16 55
Shawn Troup
29 63
TROY CONRAD
23 31
Wayne Crooks
4 4
33
Wes Helm
16 42
Total
854 2245
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Attachment E - SENCO BEES Observation Point Summary Report
Dates: 01/01/2015-02/01/2015
BBS Observations
Type:
Observation Points Summary Observer: SENCO
People
# Safe % Safe # Opportunity
%Opportunity #Condition %Condition # Marked % Marked
Ascending/ Descending 315 100.00% 0 0.00% 0 0.00% 315 36.84%
Carrying / Moving
650 100.00% 0 0.00% 0 0.00% 650 76.02%
Communication
690 100.00% 0 0.00% 0 0.00% 690 80.70%
Eyes on Task
824 100.00% 0 0.00% 0 0.00% 824 96.37%
Line of Fire
552 100.00% 0 0.00% 0 0.00% 552 64.56%
Overextending
329 100.00% 0 0.00% 0 0.00% 329 38.48%
Pace
692 100.00% 0 0.00% 0 0.00% 692 80.94%
Pinch Points
577 100.00% 0 0.00% 0 0.00% 577 67.49%
Push/Pull
420 100.00% 0 0.00% 0 0.00% 420 49.12%
Twist/ Turn
426 100.00% 0 0.00% 0 0.00% 426 49.82%
5,475 100.00% 0 0.00% 0 0.00% 5,475
PPE
# Safe % Safe # Opportunity
%Opportunity #Condition %Condition # Marked % Marked
Face-Shield/ Welding Shield 99 100.00% 0 0.00% 0 0.00% 99 11.58%
Fall Protection
234 100.00% 0 0.00% 0 0.00% 234 27.37%
Goggles/Glasses
771 100.00% 0 0.00% 0 0.00% 771 90.18%
Hand Protection
803 100.00% 0 0.00% 0 0.00% 803 93.92%
Head Protection
794 99.87% 1 0.13% 0 0.00% 795 92.98%
Hearing Protection
632 100.00% 0 0.00% 0 0.00% 632 73.92%
Personal Monitor (H2S, SO2, etc.)
695 100.00% 0 0.00% 0 0.00% 695 81.29%
Protective Clothing
674 100.00% 0 0.00% 0 0.00% 674 78.83%
Respiratory Protection
49 100.00% 0 0.00% 0 0.00% 49 5.73%
4,751 99.98% 1 0.02% 0 0.00% 4,752
Procedures
# Safe % Safe # Opportunity
%Opportunity #Condition %Condition # Marked % Marked
Confined Space Entry
71 100.00% 0 0.00% 0 0.00% 71 8.30%
Energy Isolation (LO/TO) 12 100.00% 0 0.00% 0 0.00% 12 1.40%
Hot Work
100 100.00% 0 0.00% 0 0.00% 100 11.70%
JSA/JHA Assessment
486 100.00% 0 0.00% 0 0.00% 486 56.84%
Mat'l Handling / Storage 287 100.00% 0 0.00% 0 0.00% 287 33.57%
Permit
548 100.00% 0 0.00% 0 0.00% 548 64.09%
Process Safety
219 100.00% 0 0.00% 0 0.00% 219 25.61%
Signs/ Labels
118 100.00% 0 0.00% 0 0.00% 118 13.80%
1,841 100.00% 0 0.00% 0 0.00% 1,841
Tools / Equipment
# Safe % Safe # Opportunity
%Opportunity #Condition %Condition # Marked % Marked
Barrier Tape/ Baricades 237 100.00% 0 0.00% 0 0.00% 237 27.72%
Condition
373 100.00% 0 0.00% 0 0.00% 373 43.63%
35
Grounding
103 100.00% 0 0.00% 0 0.00% 103 12.05%
Guards
153 100.00% 0 0.00% 0 0.00% 153 17.89%
Hoses
64 100.00% 0 0.00% 0 0.00% 64 7.49%
Obstructed Safety Equipment 91 100.00% 0 0.00% 0 0.00% 91 10.64%
Process Equipment
78 100.00% 0 0.00% 0 0.00% 78 9.12%
Proper Select / Use
380 100.00% 0 0.00% 0 0.00% 380 44.44%
Scaffold,ladders & stairs ect 148 100.00% 0 0.00% 0 0.00% 148 17.31%
Storage
90 100.00% 0 0.00% 0 0.00% 90 10.53%
Transportation / Travel 334 100.00% 0 0.00% 0 0.00% 334 39.06%
2,051 100.00% 0 0.00% 0 0.00% 2,051
Work Environment
# Safe % Safe # Opportunity
%Opportunity #Condition %Condition # Marked % Marked
Housekeeping
651 100.00% 0 0.00% 0 0.00% 651 76.14%
Odor
171 100.00% 0 0.00% 0 0.00% 171 20.00%
Proper Lighting
347 100.00% 0 0.00% 0 0.00% 347 40.58%
Spotter
353 100.00% 0 0.00% 0 0.00% 353 41.29%
Tripping Hazards
509 100.00% 0 0.00% 0 0.00% 509 59.53%
Weather
429 100.00% 0 0.00% 0 0.00% 429 50.18%
2,460 100.00% 0 0.00% 0 0.00% 2,460
Grand Totals
16,578 99.99% 1 0.01% 0 0.00% 16,579
36
Attachment F - 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