supervisors_and_managers_safety_audit_training v.3.3.ppt

August 8, 2007 Version 3.3 1

Introduction to DuPont Safety Principles

&PPD Safety Audit Program


“You get the level of safetythat you demonstrate you

want.”

(DuPont Proverb)


Outline Principles of DuPont’s approach to

safety Overview of PPD’s Audit Program Details of PPD’s Audit Program Forms and examples


DuPont core belief

All injuries can be prevented


Benefits of Good Safety Management

Reduction in the cost of medical and workers’ compensation

Greater productivity Improved product or research

quality Overall operation improvement


Basic Principles of Good Safety Management

Management Commitment Documented Safety Philosophy Safety Goals and Objectives Committee Organization for Safety Line Responsibility for Safety Supportive Safety Staff


Basic Principles of Good Safety Management

(cont’d) Rules and Procedures Audits Safety Communications Safety Training Accident Investigations Motivation


DuPont’s Experience A ten-year study of all serious

injuries occurring across all Du Pont sites showed that: 96% of the injuries resulted from the

unsafe acts of people or from poor work practices

Only 4% of the injuries resulted from unsafe conditions


DuPont’s Expectations for Safety Performance

Employees must: Make safety equal to all other aspects

of the job [and in PPD, safety is #1] Follow all safety rules and procedures

Management must: Accept responsibility for prevention of

injuries Accept responsibility for safety training


Supervisor’s Responsibilities Know, communicate, and enforce

existing standards Recognize the need for revised

standards Develop new procedures and rules

when necessary Train employees to follow all rules

and procedures


ES&H Responsibilities Serve as advisors when addressing

supervisors’ questions arising from audits

Perform audits as a crosscheck of the audits conducted by line management

Help to address safety issues uncovered in audits

Compile, analyze and disseminate data collected from the audits


Overview of PPD’s Audit Program


PPD’s Audit Program An opportunity to spend a few

minutes observing activities in the workplace and then discuss what you’ve seen with your employees

This is done with an eye towards safe, and unsafe, behavior

Mitigate hazards Record observations


Proposed auditing in AD areas during the shutdown

The main focus of today’s training is the situation where a supervisor is auditing his or her people in their normal work areas

It is likely that PPD supervisors will be asked to conduct safety audits of their people who are working in Accelerator Division areas during the shutdown

Audits in AD areas will be conducted in a similar fashion to those in PPD areas


FatalitiesLost Time InjuriesMedical Treatment

First-Aid Cases

Unsafe ActsUnsafe

Conditions


Inspection versus

Things Passive Experts (them) Negative Document / Follow up

Audit People Interactive (I care) Everyone (us) Positive & Negative Document / Follow

up

DuPont’s nomenclature


Purpose of PPD’s Safety Audit

Identify safe and unsafe, acts or conditions

Identify areas for improvement Follow up when mitigating actions are

indicated Accumulate data for tracking trends

related to safety


Types of safety audits Scheduled Unannounced Compliance with

standards Adherence to

procedures


Benefits of safety audits

Promote safe behavior Test for compliance with

standards Establish standards Identify weaknesses Accumulate data Prevent injuries


Who conducts PPD safety audits? Division Office Department Heads Group Leaders Supervisors ES&H Staff Project Management


Proposed frequency of audits

Division Office – Quarterly Department Heads, Level

1 Project Managers – Quarterly

Group Leaders, Level 2 Project Managers – Monthly

ES&H Staff – Monthly Supervisors, Level 3

Project Managers – Weekly


Where are audits conducted? Wherever your employees are working Group work areas Individual work spaces


Auditing

Focus on one or two activities

One location or portion of a building

One or two processes

Plan for a duration of an hour or less


Details of PPD’s Audit Program


Elements of our Safety Audit Process

Read the Audit Checklist prior to the walkthrough

Visit the work area and talk with employees (without paperwork in hand)

Mitigate any unsafe situation After the walkthrough: Complete the

checklist and the Audit Form Follow up, if necessary


What to look for during an audit

Reactions of people Positions of people Personal Protective Equipment

(PPE) Tools and equipment Procedures Housekeeping


What to look for during an audit (cont.)

Reactions of people Does anyone adjust PPE, change position, or

rearrange job when the safety auditor appears? Does anyone abruptly stop work, attach

grounds, or perform LOTO?

Positions of people Is anyone in danger of injuring himself by

pulling or lifting heavy objects? Is anyone in a position where he or she could

fall, be trapped, collide with anything, or be hit?



Personal Protective Equipment (PPE) Are employees using the required protective

equipment? Are they using the PPE properly? If not, why not? Is the PPE inconvenient to

obtain or hampering the job in some way?



Tools and equipment Are they being used properly? Are they in safe condition? Are homemade tools (not properly

designed) being used? Procedures

Are they adequate? Do they prevent allunnecessary risks?

Are they followed?



Housekeeping Is the workplace neat? Are things put away properly?


Safety Audit Checklist Safety Audit

Checklist Handout


The Safety Audit Form


The Safety Audit FormPotential Injury Severity

Severe Moderate Minor

Broken bones, dismemberment, fatality

Abrasions, cuts, injuries requiring more than first aid

First aid


When Someone is Working Unsafely

Observe; then get the person’s attention

Comment on what the employee was doing safely

Discuss with the employee The possible consequences of the

unsafe act Safer way to do the job


When Someone is Working Unsafely (cont’d)

Get the employee's agreement to work safely in the future

Discuss other safety issues of the job Ask the employee what you the

supervisor could do to make the employee’s job safer

Thank the employee


Audit Examples


Audit Example


Audit Examples


What happens to the safety audit sheets?

PPD/ES&H ESHTRK Statistics

Unsafe Acts (UA) per Audit Hour (AH) for First Year of Audit Program

0

10

20

30

40

50

60

1 2 3 4 5 6 7 8 9 10 11 12

Month

UA p

er A

H


Conclusion All injuries can be prevented Management is responsible for preventing

injuries Working safely is a condition of employment Training employees to work safely is

essential Prevention of personal injuries is good

business (and good science!) Audits can play a key role in safety And, once again …


PPD’s Audit Program An opportunity to spend a few

minutes observing activities in the workplace and then discuss what you’ve seen with your employees

This is done with an eye towards safe, and unsafe, behavior

Mitigate hazards Record observations

supervisors_and_managers_safety_audit_training v.3.3.ppt

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