1 united steelworkers & united states steel joint safety and health auditing april 29, 2010...
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United Steelworkers & United States Steel
Joint Safety and Health Auditing
April 29, 2010
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Purpose:
To assist in the protection of every employee within
U. S. Steel
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Safety – Our Key Core Value
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To be a critical, complementary safety activity to the hard work that is already taking place within the safety processes at the plants
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Establishing the foundation:
U. S. Steel and the United Steelworkers (USW) agreed to an increase in union involvement in safety and health as part of a 2004 agreement on Joint Safety Activities
This included:
Establishment of the USW Corporate Safety Coordinator for U. S. Steel
Setting the stage for Joint Safety Audits starting in 2005
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Establishing the foundation:Audit format – What Is audited?Corporate safety expectations:
U. S. Steel Life Threatening Safety Standard Practices:
- Energy Control
- Elevated Work and Fall Protection
- Confined Space Entry
- Mobile Equipment Hazards
- EOT Crane Hazards
- Gas Hazard Management
- In-Plant Railroad Operations
- Molten Metal Protection
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Establishing the foundation:Audit format:
U. S. Steel Life Threatening Safety Standard Practices:
- Each practice is broken down into a checklist of key
practice items
- Written plant documentation
- Training efforts on the practice
- Key observations of the practice implementation on the shop floor
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Mid-Atlantic Safety and Health Alliance 2K10 Conference
U. S. Steel Life Threatening Safety Standard Practices
Joint Safety and Health Auditing
Written Life Threatening Practice
TrainingImplementation
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Energy Control Program Audit
Purpose: The review of the Energy Control Program is to determine the thoroughness of the program's implementation. It is to include a written program review, review of training materials and training records, and a review of the programs implementation/integration into the facility. A review of employee knowledge through an interview process will be conducted by the auditors assigned .
Written Facility Program: Y/N Comments Score ()
1 Is a written facility lock out program in place? (MUST BE PRESENTED) In lieu of a facility program are the Corporate Guidelines utilized? (These are acceptable, if in place)
2 Does the facility program contain the program elements detailed in the corporate guidelines?
3 Are formal Energy Control Procedures developed and readily available for equipment with more than one energy source?
4 Are the Energy control procedures up-to-date? (Reviewed/revised in the last year? Ask if the department keeps hard copies and check the document for the required review date? Is it current?)
5 Are procedures in place for maintaining the continuity of energy control across shifts?
6 Is the forceful lock removal procedure in place and used? (Ask to see completed forms)
7 Are the usage of each color lock explained in the program?
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Joint Safety and Health AuditingTraining: Y/N Comments
8 Has documented Energy Control Program Training been conducted for all affected and authorized employees?
9 Do the training materials contain the program elements of the corporate program?
10 Does training both initial and refresher include a hands-on lock out component?
11 Do facility training records reflect both initial and refresher training?
12 Are all lock types & unique color thoroughly explained in the training (personal, department, continuation or carry over, and out of service locks).
13 Are the usage of lock boxes thoroughly explained?
14 Is the usage of the lock placement verification form included in the training?
15 Is the usage of the forceful lock removal form thoroughly covered?
16 Do employees have a thorough knowledge of the program and how to implement? (The interview process will cover this)
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Joint Safety and Health Auditing Field Verification: Identify lock out activity in place. Y/N Comments
17 Were pre-job instructions involving the lock out given to the employees (verbal or written)?
18 Is the employee's lock(s) used in a lock out activity properly colored and identified per the facility program? How many keys are there?
19 Has the lock out activity properly followed the appropriate Energy Control Procedure (Example: sequence of isolation and lock placement?)
20 In a group lock out activity, if a lock box is in use, is the lock verification form in place and completed properly?
21 Are all personnel working on the task accounted for on the lock box?
22 Is verification of energy isolation conducted prior to starting the task? If so how?
23 If restraints are used (blocks, pins, cans, chains, etc.) are they of an engineering design?
24 Are Out of Service Locks & Tags in place for equipment removed from service?
25 Prior to placing the equipment back in service and to release from the lock out, is a final inspection performed for personnel, tools, equipment?
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Establishing the foundation:Audit format:
Interviews with employees (hourly and salaried)
- Progress the safety process has provided for their safety
- Addressing their needs
- Talking with peers from other facilities – no retribution
- Education gained – Life Threatening Practices questions “Do they know the practice?”
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Joint Safety and Health Auditing Safety Interview: Energy Control Program
Question #
Question Correct Incorrect Comments
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What is the purpose of lockout/tagout/tryout? (To assure the hazards presented by equipment energy sources are controlled prior to the equipment being worked upon.)
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What types of energy sources must we be concerned about? (Electrical, Pneumatic, Hydraulic, Stored, Gravity, Radiation, Mechanical - (4 of 6 is correct)
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What document tells how to effectively lock out a specific piece of equipment? (The Energy Control Procedure)
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What color is your personal safety lock? ( Location dependent, most locations - red, Granite City - blue)
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How is you lock to be identified? (Permanent marking - normally name and number)
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What do you do with the second or spare key to your safety lock? (There is to be no second key)
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Who is allowed to remove your lock besides yourself? (NO one!!!!)
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Establishing the foundation:Audit format:
Physical conditions and housekeeping:
- Compliance issues
- Recognized hazards
- U. S. Steel best-in-class housekeeping and physical conditions
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Joint Safety and Health Auditing Electrical Control Rooms and Substations :
13 Motor control rooms, motor control centers and substations must be secured and locked.
14 Warning signs must be posted (e.g. Danger High Voltage/Authorized Personnel Only - 13800 Volts).
15 Clean dielectric rubber mats are required in front of switchgear or breaker cabinets.
16 Electrical panels are to be closed.
17 Flammable and/or combustible material (i.e. wood, cardboard, paper) is not to be stored in proximity to electrical equipment. Metal ladders are not to be used in the proximity of electrical equipment.
Handrails
18 Protection of open sided platforms and walking/working surfaces must be complete with no damaged and/or missing handrails, mid-rails or toe boards.
19 Steps with more than 4 risers must have handrails.
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Establishing the foundation: Make up of the Audit Teams:
- Union Safety Representatives
- Operating and Maintenance Managers
- Safety Supervisors
Different viewpoints
Different safety skills
Different sets of eyes
All involved for the same reason – Employee Safety
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Establishing the foundation: Make Up of the Audit Teams:
Each party selects their auditors
Based on mutual trust ensuring:
- Attitude is not an issue
- Strong commitment to safety
- Will work to get the task done
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Establishing the foundation:Additional value for the Audit Team
- Seeing other operations
- Meeting like Managers and Union Safety Representatives
- New ideas to take back
- Reinforcement of U. S. Steel values and implementation
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Establishing the foundation:Auditor training
1 day of training for new auditors
- Life Threatening Safety Standard Practice review
- Physical conditions exercise
- Interview protocol
- Safe task evaluations
- Strain and sprain recognition
- Recordkeeping (U. S. Steel programs)
- Auditing as a team
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Mid-Atlantic Safety and Health Alliance 2K10 Conference
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History:
2005 activities:
- 15 audits of facilities
2006 activities:
- 1-day training class for all auditors
- 16 audits of facilities
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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History:
2007 activities:
- Equal numbers USW Safety Representatives and U. S. Steel
Managers
- 1 day of training for new auditors
- 18 joint audits of facilities
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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History:
2008 activities:
- 1 day of training for new auditors
- 17 joint audits of facilities
- The audits were conducted while 2008 contract negotiations were under way
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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History2009 activities:
- Experienced auditors
- 8 audits of facilities in full operation
2010 activities:
- 1-day training classes for new auditors
- 17 audits scheduled starting May 2
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Auditing the plant:
Meet the night before:- Introductions
- Determine strategy
- Set up teams and area of responsibility
- Go over general rules
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Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Auditing the plant: Opening meeting with the
plant’s personnel
Set ground rules - No discipline
Introduce teams and areaassignments
Go over plant rules
Arrangements for back turn auditing
Joint Safety and Health Auditing
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Auditing the plant:
Walk, Look and Listen
Research what we see if not sure
Daily Close Out Meeting
- 3’s and 3’s
- Plans for the next day
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Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Auditor’s meetings:
Daily calibration of progress
Reassignment of resources
Daily data input
End of week report writing
- Draft report of findings and impressions
- Corrective action spreadsheet
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End of the Week Draft Report and Spreadsheet preparation:
Meticulous detail and geographically correct
Positive items reviewed
Items needing attention
Consensus of the team, not a single person
Joint Safety and Health Auditing
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Close Out Meeting :
The Audit Team presents its consensus findings
Review the major issues
Sets timeline for plant responses and distribution
Report circulated within one week to copy list, which includes Operating Vice
Presidents, Executive Vice President and Union Officials
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Follow up :
Monthly progress on corrective actions are sent to corporate office and tracked to completion
Corrective Actions completion goals:
- 85% in 60 days
- 95% in 90 days
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Lessons learned :
Positive cooperative effort
Attitudes checked at the door
Consensus does happen
Definite improvements seen
Shift from conditions and housekeeping to procedures, task evaluations and better safety practice implementation
Joint Safety and Health Auditing
Mid-Atlantic Safety and Health Alliance 2K10 Conference
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Questions?
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United Steelworkers & United States Steel
Joint Safety and Health Auditing
April 29, 2010
Mid-Atlantic Safety and Health Alliance 2K10 Conference