operating management - reduce fifr

7/28/2019 Operating Management - Reduce FIFR

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REDUCE

Fatigue Incident Frequency Rate

(FI

FR)

Adrianus D 2911 2615

Denastri Ramli 2911 2624

Beniardi M 2911 2627

Meiliza 2911 2639

Sigit Saputro 2911 2647


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Project Background

Fatigue related incidents are still of major issue within

KPC operations.

Fatigue has caused serious incidents including fatality,

potential fatality and high cost property damage.

Various programs have been conducted but FI-FR has

not been reduced significantly.

Change of shift crews roster from 8 hrs to 12 hrs may

increased the risks of fatigue.

No practical standard fatigue guidelines across KPC.


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Project Summary

GOALS :

Reduce Fatigue Incident Frequency Rate (FI-FR) to 0.5 per

million man hour

Eliminate Potential Fatality incident due to fatigue FOCUS AREA :

For MOD, MSD, and Mining Contractors (CMD)

BOUNDARIES :

Review and programs will include MOD, MSD and Mining

Contractors.

No major capital expenditures


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Benefit of The Project

This project will provide potential of reducing costs

of incident and saving of property damage loss up to:

$ 180,750.00 - annualized from history of:

Operation Time Periode Loss due to Fatigue

PTDH Mining Ops 2007-Apr 2009 US$53,676.00

TCI Mining Ops 2007-Apr 2009 US$ 15,300

Pama Mining Ops 2007-Apr 2009 US$ 200,587.00

KPC MSD Ops 2007-Apr 2009 US$ 10,102.00

KPC MOD Ops Jan-Apr 2009 US $ 20,299.00


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Fatigue Incidents Record 2007-2009


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Historical FR (Before Project)

Project of Reducing FI FR was introduced on mid-semester 2009.

Based on historical FI FR from 2003 until 2009:

- Average FI FR was about 0,88 per million workinghours

- Moving Range was about 0,55

Link data for historical FI FR : link
http://localhost/var/www/apps/conversion/tmp/scratch_5/Fatigue%20Inc%20Stat.xlsxhttp://localhost/var/www/apps/conversion/tmp/scratch_5/Fatigue%20Inc%20Stat.xlsx


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Chart Limit Before Project


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Range Limit Before Project


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PARETO of Fatigue Incident Root Causes

9

0

10

20

30

40

50

60

Not reporting

when fatigue

Sleep disturbed Domestic

activities

Traveling Hobbies Rest time not

used

New employee

Numberofincident

Fatigue Incidents 2007-2009


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10

Survey Result: Why Not Reporting

21.4%

19.0%

14.4%

35.9%

25.8%

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

35.0%

40.0%

Malu/takut/khawatir

penilaian buruk

Tidak mengetahui

aturan wajib lapor bila

fatigue

Laporan fatigue tidak

ditanggapi pengawas

1 bulan terakhir

pengawas tidakmenanyakan fatigue

Terpengaruh

kebiasaan/rekan kerja

Note: MOD all respondents are aware on requirement for reporting when fatigue


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Survey Result : Alarming Facts

78.0%

22.0%

51.3%

33.4%

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

80.0%

90.0% 1 bulan terakhirpernah fatigue tetapbekerja

1 bulan terakhir > 3xfatigue tetap bekerja

1 bulan terakhir

tidak pernahmelapor saat fatigue

Tidak selalu bisatidur minimal 6 jam

setiap hari


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15.0%

11.3%

5.5%

4.6%

6.2%

15.9%

11.5%

13.3%

14.9%

0.0%

2.0%

4.0%

6.0%

8.0%

10.0%

12.0%

14.0%

16.0%

18.0%

Domestic activities

Hobbies

Second jobsTravelling

Social activities

Uncomfortable room

Family

Environment

Others

Survey Result: Sleep Disturbance


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91.4%90.6%

89.4%

84.0%

80.0%

82.0%

84.0%

86.0%

88.0%

90.0%

92.0%Merasakan

pengaruh positif

fatigue alarm

Prosedur fatigue

saat ini sudah baik

Manfaat fatigue

check pada jam

kritis

Tindakan disiplinmeningkatkan

kesadaran

Survey: Positive Feedbacks


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14

Proposed Solutions & Progress

No Action Progress

1 Improve Awareness:

- Trainer Training: Fatigue for Spouse

- Trainer Training: Fatigue for shift workers

- Sticker: Ngantuk Lapor!

- Training and refresher for Spouse

- Training and refresher for shift workers

100%

90%

100%

On going

-

2 Improve implementation of fatigue check by

supervision pre-shift and during critical hours

On going

3 Improve KPC fatigue alarm system to enablenotification to dispatcher

Proposal to be submittedto Mgt

4 Review shift roster to minimize potential

fatigue after long day offs

Options reviewed (need

further study)

5 Radio messages on critical times (FM &

communication radio)

On going
http://localhost/var/www/apps/conversion/tmp/Roster%202010(4%20day).xlshttp://localhost/var/www/apps/conversion/tmp/Roster%202010(4%20day).xls


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15

Results

Milestones completed to date :Stickers Ngantuk Lapor installed in equipment cabin

Fatigue Management for Spouse Training Material

has been reviewed and facilitators trainingconducted

Fatigue Awareness Training material for shiftworkers reviewed (facilitator training scheduled)

Proposal for upgrading KPC fatigue warning systemhas been submitted (cost US$ 55,000.00)


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FI FR After Project

To see the affect of this project, we try to look upFI-FR after 2009 (started from Jan 2010).

Based on data FI FR from 2010 until March 2013:

-Average FI FR was reduced to 0,672-Moving Range was reduced to 0,36

Link data after project : link


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Chart Limit After Project


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Range Limit After Project


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19

Capability

To check the capability for achieving FI-FR targetto 0,5, it can be checked based on before

project and after project:

Keterangan X? USL LSL Cp Cpk Control Capablity

FR BEFORE PROJECT 0,543 0,875 0,50 0 0,153 (0,23) Out of Control Not Capable

FR AFTER PROJECT 0,341 0,672 0,50 0 0,244 (0,17) Out of Control Not Capable


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20

Achievement

The successful implementation of projectinitiatives has resulted in:

Average FR reduced during from Jan 2010

March 2013 from 0,88 to 0,672.

The intangible benefit realized so far :

YTD 2009: No fatigue incident resulted in

potential fatality (PF) compared to 4 fatigue

incidents resulted in PF in 2008


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21

How To....

In

Control FI-FR:

To make Capable to achieve FI-FR = 0,50 :


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22

Maintain Gains (Sustainability Plan)

Monitor on going implementation of Fatigue Management

Training and refresher for shift workers and for spouses

by trained facilitators at each div/dept/contractors.

Monitor the implementation of fatigue check by

supervisors (pre-shift and at critical times)

Line management to perform random check of fatigue

check by supervisors

Review implementation of dispatch improvement to

enable notification to dispatcher


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23

What Next?

Continue review of SOP / Guidelines onFatigue Management and get appropriate

approval for implementation.

Further review of alternative shift roster

for MOD


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24

Lessons learnt

Valuable experience gained by all team members during

involvement in the project: new knowledge,

perspectives, and team work.

Challenges faced during project:difficult to maintain good team members attendance

due to urgent matters, e.g. incidents.

collecting and compiling data and surveysEnrichment from sharing programs and experience from

other divisions / contractors involved.


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INGAT: NGANTUK, LAPOR!!

THANK YOU

& KEEP SAFETY

operating management - reduce fifr

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