S&B Plant Services

Best Practices 2010LyondellBasell Houston Refinery

Watch Out!Stop, Step-back and Think

• This program is a paperless behavioral hazard recognition and elimination program focusing on “Watch-out Situations” based on recent incident root cause analysis. The entire program is focused around one question! “What is the worst thing that could happen to me and how can I prevent it?” If an employee encounters one of the “Watch out” situation they must:

• Stop– Stop right where you are; you are performing a dangerous task or you have recognized the

potential for a hazard.• Step-Back

– Look at your surroundings and identify any hazards.– Picture watching yourself doing the task you were completing. (Any opportunities to

improve?)• Think

– How can you correct any hazard you identified?– How can you improve on what you were doing?– How can you protect yourself?

• This program is difficult to measure by anything except results. When an incident occurs the group of employees must identify which “Watch out” situation could have been recognized to prevent the accident. Before long this action became second nature. These following slide depicts “watch out” we are looking for:

Watch Out! SituationsIf encountered Stop Step-back and Think

1. You find yourself preparing to work in an area you have never seen before.2. You find yourself working alone and do not have communications with your

crew or supervisor. 3. You find yourself suddenly working above or below another employee. 4. Safety showers, evacuation points and escape routes are not identified 5. Your Instructions and assignments do not clarify your work scope, plan and

hazards. 6. Setting up the work tasks or work area without an STA/JSA. 7. Weather has changed causing your work environment to change.

8. You are working with people you do not know. 9. You are doing a task you have never been trained to do. 10.You are moving a piece of equipment and can not see everything around

you. 11. If you find yourself frustrated with your task, supervisor or fellow employees.

S.S.T. (Stop Step-back & Think)

• S.S.T. is a mental assessment of what can happen and how you can mitigate or prevent potential hazards.

• It only takes about 5 seconds. Before each task ask yourself:– What is the worst thing that can happen? and– How can I prevent this from happening?

• We do this subconsciously already on every task. – Why don’t you grab a hot pan off the stove?– Why don’t you stick your hands in the ends of a

pipe?

S.S.T.(Stop Step-back & Think)

• Stop– Stop right where you are; you are performing a

dangerous task or you have recognized the potential for a hazard.

• Step-Back– Look at your surroundings and identify any hazards.– Picture watching yourself doing the task you were

completing. (Any opportunities to improve?)• Think

– How can you correct any hazard you identified?– How can you improve on what you were doing?– How can you protect yourself?

Behavioral Based Safety ProgramP.O.P. (People Observing People)

• People are the most important element of a safety program. S&B’s P.O.P. program engages our team members in a way where they know they are the backbone of our safety program.

• Data from POP is reviewed regularly and discussed with the workforce at the morning safety meetings and posted for their review.

• This program is designed around observing an employee, giving feedback on the observation and documenting the findings.

Behavioral Based Safety ProgramP.O.P. (People Observing People)

• Positive feedback is the key to the success of our program. We have been coaching our employee on how to speak up.

• Before approaching an employee that has an opportunity to improve their actions or their environment, recognize three positive things with their situation. During your feed back conversation address the three positives items first then ask the employee how they could improve in their area of opportunity.

POP Enhanced Behavioral Based Safety Program:

• In May 2010 we realized that we were experiencing an increase in At-Risk conditions being reported on our employee observation cards and a decrease in true behaviors being recognized. With help from the employee safety committee and a pool of safety professionals we compiled 48 different behaviors that can adversely affect employees in the field.

• By presenting the employees with these behaviors in a written form (POP Enhanced Program Hand Out) they are given the opportunity to read a description of the behaviors, therefore essentially teaching them what an unsafe behavior truly looks like.

• By giving the employees a description of these behaviors both the observer and the observed employees are gaining knowledge on proper behaviors.

• To help facilitate this program change, we hired a safety professional whose primary responsibility was to teach each and every employee on the site how to complete a true behavioral based observation in a one-on-one field setting.

Enhanced POP Method and Results• The results were amazing. We increased

the number of observations significantly. At the same time we also noticed an increase in at risk behaviors being recognized.

• We use this enhanced program data to find target areas for daily tool box meetings and supervisor talking points. Each card is reviewed, evaluated and entered by a member of the site safety staff.

• A weekly report is assembled and the findings are posted and discussed with management and the craft employees.

• To ensure that our results are accurate every two weeks the employee safety committee reviews the observation cards and makes recommendations on how to further advance the program.

• In this time frame we saw a drastic decrease in safety incidents and accidents.

Enhanced POP Method and Results

POP Enhanced Behavioral Based Safety Program:

1. Is the employee using the proper lifting and climbing techniques?

a) Did employee lift with legs not back?b) Are tools being raised to upper levels; not carried?c) Is there three points of contact used?d) Is a Yo-Yo being used over 13 feet?

2. Was the employee observed in the line of fire?a) Did employee keep their hands in a safe position?b) Were sparks being thrown at employee?c) Was someone working above or below employee?d) Did employee put others in the in the line of fire?

3. Is the job set up properly and kept neat?a) Are employees walking over cords and hoses?b) Is trash put in proper containers?c) Did employee put tools in a secure location?d) Is excess material removed as the job progresses?

4. Have all the hazards been identified?a) Did the employee put the proper tagged barricades?b) Are hot pipes covered or barricaded?c) Is the employee working near a tripping hazard?d) Are overhead hazards identified?

5. Is the employee using his/her tools safely?a) Is employee using guards on all tools?b) Did the employee check the tools monthly inspection?c) Are the right tools being used?d) Does the employee have the proper handle on the

tool?6. Are any shortcuts being taken?

a) Was an improper tool used because it was easier?b) Were spoils piles and tools left close to an

excavation?c) Was an area accessed without a proper work

platform?d) Were cheaters used to tie off improperly?

7. Is mobile equipment being used safely?a) Did the employee use proper hand signals?b) Was equipment moved without a spotter?c) Did the employee do a 360 degree walk around?d) Did the employee wear a seatbelt?

8. Is the employee aware of the worst thing that could happen?

a) Can the employees show you the eye wash station?b) Can the employee contact emergency services

quickly?c) Do employees know where to go in an evacuation?d) Do employees know what process unit they are in?

9. Are fire hazards removed?a) Are aerosol cans located near hot work?b) Is trash or flammables located near hot work?c) Did the employee check the fire extinguisher today?d) Does the employee have a fire watch present?

10. Is the employee following the STA and permit requirements?

a) Did employee sign STA?b) Is a permit completed for the task at hand?c) Is the employee wearing permit required PPE?d) Did employee read the permit?

11. Is the employee’s PPE in order?a) Did employee complete a harness inspection?b) Is the employee’s H2S monitor in the “Breathing

Zone”?c) Did the employee fit their harness snugly?d) Is double eye or eye/face protection being used when

needed?12. Are proper rigging practices being used?

a) Are softeners being used when needed?b) Did the employee inspect the rigging?c) Are shackles being used?d) Is excess rigging hanging or not being used?

POP Enhanced Behavioral Based Safety Program:

POP Enhanced Behavioral Based Safety Program:

Questions?