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Inspection Department Safety Management System Manual Document Responsibility: Manager, Inspection Department 9 August 2010 IDSMS-01
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
TABLE OF CONTENTS
INTRODUCTION Priority of Safety and Loss Prevention Fig 1. Saudi Aramco Loss Prevention Policy Our Safety Management System The Eleven Elements of the Saudi Aramco Safety Management System 1. Leadership and Accountability Safety Responsibilities Fig 2. Safety Responsibilities of Managers, Employees and Contractors Accountability for Safe Operation of Vehicles Fig 3. Inspection Department Safe Driving Contract Performance Planning Process Resources Performance Measurement Organizational Safety Performance Individual Safety Performance Employee Involvement Reward and Recognition Programs Discipline Process 2. Risk Assessment and Management Fig 4. Inspection Department Risk Assessment Process. 3. Communications Safe Operations Committee Fig 5. Inspection Department Safe Operations Committee Charter. Safety Communications Meetings Safety Films and Slogans Safety Suggestions Education Campaigns 4. Competency and Training Safety Training Fig 6. Inspection Department Safety Training Matrix New Employee Orientation Process Fig 7. Inspection Department New Employee Orientation Checklist 5. Asset Integrity Quarterly Safety inspections (QSI) 6. Safe Operations 7. Contractors, Suppliers and Others 8. Emergency Preparedness Environmental Impact 9. Incident Reporting and Analysis Measurement and Analysis Page 2 of 24 Printed copies of this document are uncontrolled. Page 4 4 5 5 5 5 6 6 7 7 7 8 8 8 8 9 9 9 10 10 11 11 12 12 13 13 13 13 13 14 14 15 15 15 16 16 16 16 17 17
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
10. Community Awareness and Off The Job Safety Community Safety Involvement Off the Job Safety 11. Continuous Improvement Self Assessment Benchmarking External Safety Management Reviews Overall Review of Program Appendix I Terms and Definitions Appendix II Procedural References
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Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
INTRODUCTION
Inspection Department has developed the following written safety management system manual to help us to achieve our safety vision: Believe in safety to finish each day incident free for the well being of ourselves, families, company and society (on and off-the-job). This written program also serves to define our safety management system, aligned with the principles of the Saudi Aramco Safety Management System Manual.
Fig 1 Saudi Aramco Loss Prevention Policy, 2009 Page 4 of 24 Printed copies of this document are uncontrolled.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Safety Responsibilities We recognize that safety is an individual responsibility as success in safety requires all personnel to fulfill their expected safety responsibilities. Fulfilling safety responsibilities is a condition of employment for company managers, supervisors and employees and a contractual obligation for contractors. Fig 2 below clearly communicates our expected and foundational safety responsibilities. Manager/Supervisor Safety Responsibilities:
Communicate safety rules and standards to all personnel; Provide appropriate resources, tools and training for employees; Award contracts using safety, health and environmental criteria; Conduct documented safety meetings; Correct unsafe conditions and acts promptly; Conduct routine safety and environmental inspections and tours; Maintain facility emergency plans and conduct regular emergency drills; Investigate injuries, spills and other incidents; Periodically review facility and employee safety performance.
Contractor Responsibilities:
Ensure that their employees and their contractors are trained in SA safety rules and competent in their craft or skill; Comply with all SA rules, policies and procedures; Report injuries, spills and incidents immediately to S person-in-charge; Report unsafe conditions promptly to SA person-in-charge; Operate SA equipment only with SA approval; Hold pre-job meetings and other safety meetings during the job.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Accountability for Safe Operation of Vehicles Inspection Department places accountability for safe operations of company vehicles solely on the employee whose job requires operation of a Saudi Aramco vehicle or rental car while on company business. Inspection Department utilizes a Safe Driving Contract to establish this form of accountability. As the company vehicle is not the property of the employee, it is fair to remind him that certain safety responsibilities and adherence to rules are reasonably expected. This Safe Driving Contract, shown below in Fig 3, helps to establish accountability for safe operations of vehicles. This form is reviewed and signed by new or transferred employees to Inspection Department who are required to operate vehicles. This contract is part of the New Employee Orientation Process described below. Other communication tools and processes to influence offthe-job vehicle safety and traffic safety in general are described later in this program.
Performance Planning Process Each year, Inspection Department management will set clear loss prevention goals and objectives. The SOC will be utilized for proposal and approval of such annual performance objectives, e.g., implementation of new orientation process. Additionally, a proper mix of leading (reflects
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
activities) and lagging safety performance (reflects lagging failure data) indicators will be utilized to gauge organizational safety performance as discussed below. Resources As listed above in the safety responsibilities of manager, supervisor, employee, contractor, they will ensure that appropriate training, materials, and personal protective equipment is available for all employees. Additional technical resources will be requested as necessary from such groups as Area LPD staff or from other technical units. Performance Measurement Inspection Department has established processes to ensure safety performance measurement is properly applied for the organization. Additionally, proper appraisal of individual safety performance will be conducted as part of the Saudi Aramco Performance Management Process (PMP). Organizational Safety Performance A typical mix of leading and lagging indicators will be proposed and adopted annually through the SOC. Potential leading or proactive safety performance indicators are: % training completed % safety meetings completed Number of inspections (QSI) completed Ratio minor/major injuries reported
Potential lagging or reactive safety performance indicators are: Industrial disabling injury (IDI) rate Number of Motor Vehicle Accidents (MVA) Property damage (Dollar value)
Individual Safety Performance - PMP All employees within Inspection Department receive annual performance appraisals via the Saudi Aramco Performance Management Process (PMP), including safety performance. Safety performance should be measured against total safety performance reflected by the safety responsibilities listed above in section 1, not just number of injuries/incidents. As these responsibilities reflect primarily proactive safety actions on the part of supervisors and employees, the following factors should be considered for individual safety performance, in order of importance:
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
1. Proactive attitude accepts safety responsibilities for self, upholds policy, % training, % meetings attended/led 2. Compliance in area observed behavioral compliance to safety rules, uphold rules in area to others 3. Correction/follow-up corrects safety items and open review items promptly 4. Housekeeping reflects safety standards maintained in area 5. Injury data rate, severity, trends, repeat injuries, ratio minor/major injuries
Employee Involvement Inspection Department recognizes the importance of employee involvement in achieving safety success. Involvement may come in many forms. Examples include: suggestions; participation in safety meetings; participation in investigations; process improvements; and education campaigns. Supervisors will strive to involve employees and utilize them as an important resource, yet not delegate direct safety responsibilities. Reward and Recognition Programs In accordance with the principles of employee reward and recognition in the SMS Manual and existing GI, Inspection Department has established a safety recognition program. This activity is also a part of continuous safety improvement discussed in section 11. The intent of the program is to recognize primarily team safety achievement and celebrate safety success. Its purpose is not to displace the other important elements of the safety program as working safely is a condition of employment within Saudi Aramco. Therefore, the annual award is an award to be earned by the entire department in recognition of an injury-free year, not a prize. The SOC will review progress and approve selection of awards for all department employees, contingent on achieving no injuries resulting in days away from work. Employees are encouraged to submit safety-related suggestions as part of the existing company innovation process. Additionally, exceptional safety initiatives by individuals or groups of employees may be selected and recognized by the SOC and Department Manager. Such initiatives must be self-initiated, contribute to significant safety gains and be verifiable in producing results. Discipline Process In Inspection Department, working safely is a condition of employment and individual safety responsibilities are well defined. Therefore, discipline as a safety training tool available to the supervisor should be rarely applied. When applied, its purpose is to achieve a desired behavior with a positive outcome, not to punish an employee for having an injury as it is too late at that point. Potential examples of where discipline may be applied include repeated failure to comply with established safety rules, failure to report injuries or incidents immediately, repeated injuries or incidents of the same kind, or horseplay. The level of disciplinary action taken will be determined
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
by supervision in accordance with the severity of the offense and existing Saudi Aramco policy, e.g., verbal warning, written warning, suspension, and termination.
Standards: Annual review at minimum or as determined by need Revised risks and program published by January 31 of new year
Training: Safe Operations Committee trained in basic risk assessment and management
Fig 4 Inspection Department Risk Assessment Process The identified safety risks for the department and personnel are associated with injury prevention and the principles of behavioral safety. In summary, they are: 1. Vehicle Safety (data indicates highest % of occupational fatalities in company) 2. Office Safety (electrocution, falls, workstation ergonomic risks identified) 3. Fall Protection (data indicates highest % of disabling injuries in company)
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
4. 5. 6. 7. 8.
Contractor Safety (subject to similar risks as employees) Operational risk (for limited personnel who visit plant sites, emergency actions) Off-the-job Safety (numerous risks including vehicle safety) Radiation Safety Environmental and Materials Safety
3. Communications:
Communicating our Safety Standards There are a variety of communication tools and processes in Inspection Department to ensure our safety standards are clearly communicated to employees and contractors in our work areas. These are further described below. Safe Operations Committee (SOC) The Inspection Department SOC is the primary communication forum for safety management direction and performance. The SOC also serves as a forum to review and decision process improvements, later to be properly communicated to all employees. The SOC meets on a regular basis and is chaired by the Department Manager. The intent of Inspection Department SOC is to be proactive in applying modern safety management principles versus a traditional reactive approach, e.g., review of incident reports. To ensure this approach, a charter is utilized for the SOC, shown in Fig 5.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
CHARTER SAFE OPERATIONS COMMITTEE INSPECTION DEPARTMENT Date: ________________ Purpose: To provide a forum to ensure safety and loss prevention matters are equally managed and communicated in Inspection Department. Applicable to all personnel and affected facilities of Inspection Department. Quarterly meetings at a minimum or as requested by management. Typically less than three (3) hours. 1. 2. 3. 4. 5. 6. Opening by Chairman Safety Performance Review mix of leading and lagging indicators (15 minutes) Employee Recognition recognition of achievement by individuals or groups (15 min) Review of Old Business open items including review of minutes (30 min) New Business - identified risks or issues; proposals for new or upgraded processes (60 minutes) Education presentation on emerging risks, company-wide initiatives (30 min) Manager (Chairman) Superintendents Health and Safety Coordinators Contractor Representatives LPD Representatives
Members:
Fig 5 Inspection Department Safe Operations Committee Charter. Safety Communications Meetings Safety meetings are a formal communication process in the Inspection Department, resulting in documented quality communication between supervisors and employees. Each unit will conduct a safety meeting on a monthly basis, with minutes of the meeting and attendees documented. Normally these meetings will be led by the unit supervisor and employee involvement will be encouraged. Typical topics will include brief review of past injuries and incidents (no names), identified risks, correction of inspection items, off-the-job safety issues, and special topics or new initiatives. Topics, materials, and media may be supplied, developed, or suggested by the Manager, the Division Heads, the Unit Heads, Loss Prevention Department (LPD), the Safety Coordinators, and individual employees.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Safety Films and Slogans Safety films are available from; The Audiovisual Film Library Room A-116 LIP Bldg 3150, Dhahran Phone: 872-9051 / 872-9067 Fax: 872-9073 Hours: 8:00-11:30am and 12:00-3:00pm, Saturday to Wednesday Safety Suggestions Employees are encouraged to make suggestions which they feel might enhance safety, productivity or efficiency. Suggestion forms are available for this purpose. If a suggestion is implemented, the employee will be recognized by management. Employees will receive feedback on all suggestions submitted. Education Campaigns Occasionally the company or the department individually will promote a safety education campaign for a particular risk, e.g., fire safety or fall protection safety. These are designed to costeffectively concentrate on a particular safety issue on a large scale for maximum impact as endorsed by management. Therefore, Inspection Department will participate in such education campaign as a visible supporter of such campaigns and will contribute resources as necessary.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Inspection Department Safety Training Matrix Employee Group I. New/transferred employees II. Employees to drive SA vehicles III. All employees IV. Supervisors V. Supervisors VI. Supervisors VII. All employees Course Number 1 2 3 4 5 6 7 R R R R R O O
Course descriptions: 1: New employee orientation for new/transferred employees 2: Driver Improvement Program, one-day plus observed driving by supervisor. Frequency: 3 years 3: Safety training in general safety responsibilities and rules. Frequency: Annual 4: Supervisor Injury Investigation Workshop (LPD). Frequency: 3 years 5: Safety Leadership Workshop (LPD): Frequency: Once 6: Fire Extinguisher Training: 7: First Aid/CPR. Frequency: 3 years and annual refresher
Fig 6 Inspection Department Safety Training Matrix New Employee Orientation Process A very important starting point is the new Employee Orientation Process that not only properly communicates our safety rules but also tells employees on Day 1 of employment that personal safety is an equal value in Inspection Department. The employee supervisor is responsible for ensuring safety orientation is completed. The New Employee Orientation Checklist below in Fig 7 reflects the orientation process.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Inspection Department New Employee Orientation Safety Checklist Action Responsible Person Complete/ Date
1. Safety responsibilities 2. Department office layout and exits 3. Emergency response instructions, alarms 4. Assembly points 5. General safety rules 6. Office safety rules and housekeeping 7. Vehicle safety rules 8. Safe Driving Contract 9. Driver Improvement Program 10. Reporting of unsafe conditions 11. Reporting of injuries, incidents 12. Environmental issues recycling, etc. 13. Off-the-Job Safety ____________________________ ______________ Employee Signature Date Completed Checklist maintained in employee personnel file. Fig 7 Inspection Department New Employee Orientation Checklist
5. Asset Integrity:
The Inspection Department shall maintain asset integrity through its life cycle to protect people, property, and the environment. All assets shall be suitable for the intended service and support safe, reliable operations. Design, construction, operation, maintenance, and decommissioning shall be managed through the assets life cycle consistent with industry practice and based on sound business management principles. Quarterly Safety Inspection (QSI) One purpose of the QSI is to maintain asset integrity through scheduled physical inspections of all facilities, to track and correct safety findings, and to document the closure of a finding. Quarterly Safety Inspection shall include all the requirements listed in Saudi Aramco general instruction # 6.011 Quarterly Safety Inspection
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
6. Safe Operation:
The Inspection Department will define the measures needed to establish and maintain operational control procedures to ensure monitoring and operating instructions are properly identified, issued and controlled. The objective is to ensure that all relevant documents necessary for proper task performance and facilities management are created and available in order to mitigate and control, to the extent possible, the Inspection Departments significant health, safety and environmental aspects.
8. Emergency Preparedness:
Inspection Department will communicate the basic emergency response plans for buildings where it is not the proponent owner, e.g., Community Services, of the building and organize (floor wardens) to execute the plan properly. Additionally, employees will participate in the emergency drills scheduled by the proponent owner. In buildings where Inspection Department is the sole proprietor of the building, an emergency plan will be developed with the assistance of FPD and Community Services including organization, resources, training and communications. A minimum of one fire and/or other type emergency drills per year will be scheduled for these structures as approved by the unit supervisor. The SOC will review the adequacy of such plans annually. Environmental Impact In accordance with the Loss Prevention Policy and related environmental policies, we are committed to minimizing environmental impact in our work activities. Environmental impact is often directly linked to a safety failure, e.g., spills or housekeeping clutter and paper, and can therefore be minimized. There are many safety issues associated with proper waste management and handling practices of the materials we utilize in our work areas such as printer cartridges or certain chemicals. In general, Inspection Department will promote a Reduce, Reuse and Recycle philosophy to minimize overall impact and waste in our work areas.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
The SOC will review measured performance against input from these processes and other leading indicators to make adjustment in program direction as necessary. The LPD is available to assist with analysis and recommendations as necessary.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
work and naturally influence will occur, e.g., fall protection, electrical safety. Supervisors will work to influence unsafe activities and educate employees through safety meeting topics and education campaigns. Off-the-job safety materials will be acquired from LPD, FPD and other organizations to help educate employees and their families on risks and proper precautions.
External Safety Management Reviews External reviews of our existing safety management system (program) can provide a valuable outside look at Inspection Department. Saudi Aramco Executive Management Safety Reviews produce visits to facilities to gauge safety progress and may include some of our employees. Additionally, other safety management reviews typically administered by LPD are organized to examine the safety management system in place for organizations such as our department. If examined by any of these type reviews, Inspection Department will support this effort fully with prompt responses to recommended actions, approved by the SOC.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Overall Review of Program Finally, a structured examination of the entire safety program or system and this document helps to promote improvement. Therefore, Inspection Department is committed to review and revision of this document annually by the SOC with a complete revision required every three years.
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Health Safety and Environment (HSE) - conditions and factors that affect the well-being of employees, temporary workers, contractor personnel, visitors and any other person in the workplace, or on the environment. HSE aspect describes any element of the Inspection Departments activities or services that can have an impact on OHSE conditions or factors. HSE Management System - part of the overall management system that facilitates the management of the HSE risks associated with the business of the organization. This includes the organizational structure, planning activities, responsibilities, practices, procedures, processes and resources for developing, implementing, achieving, reviewing and maintaining the organizations HSE policy Health Surveillance - monitoring health of employees to detect signs or symptoms of work related ill health so that steps can be taken to eliminate, or reduce the probability of, further harm Ill Health - identifiable disease or adverse health condition that is judged to have been caused by or made worse by a persons work activity or environment NOTE: this is sometimes referred to as occupational work-related ill health. ID Community Inspection department employees, contractors, general public, company assets, or any other affected or interested party. IDHSE objectives - goals, in terms of OHSE performance, as determined by the Inspection Department in support of Saudi Aramco Loss Prevention objectives. Incident - event that gave rise to an accident or had the potential to lead to an accident. NOTE: an incident where no ill health, injury, damage, or other loss occurs is also referred to as a near-miss. The term incident includes near-misses. Interested Party - individual or group concerned with or affected by the OHSE performance of an organization Management System - series of elements for establishing policy, objectives and arrangements for implementation and continual improvement Non-conformance - any deviation from work standards, practices, procedures, regulations, management system performance etc. that could either directly or indirectly lead to injury or illness, property damage, damage to the workplace environment, or a combination of these
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Organization The Inspection Department. This shall include all sub-tiers operating under the auspices of the Inspection Department Manager Performance - measurable results of the OHSE management system, related to the organizations control of health and safety risks, based on its OHSE policy and objectives NOTE: performance measurement includes measurement of OHSE management activities and results. Record document stating results achieved or providing evidence of activities performed. Risk - combination of the likelihood and consequence(s) of a specified hazardous event Risk assessment - process of identifying hazards and evaluating the risks to health and safety arising from these hazards taking account of the existing risk controls (or, in the case of a new activity, the proposed risk controls), estimating the magnitude of risk and deciding whether or not the risk is tolerable Risk control - selection and application of suitable measures to reduce risk Safety - freedom from unacceptable risk of harm Status review - formal evaluation of the IDHSE management system Safety Culture - product of individual and group values, attitudes, competencies and patterns of behavior that determine the commitment to, and the style and proficiency of, an organizations approach to health and safety Tolerable Risk - risk that has been reduced to a level that can be endured by the organization having regard to its legal obligations and its own OH&S policy Worker Representative - safety and health representative and or representative of employee safety and health
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
Appendix II
Procedural References:
1. Leadership & Accountability: HSEP 01-3.1-01 Department Organization and Structure HSEP 01-5.0-01 Management Review 2. Risk Assessment and Management: HSEP 01-2.1-01 Hazard Identification and Risk Assessment HSEP 01-2.2-01 Legal and Other Requirements HSEP 01-2.3-01 Objective Setting 3. Communications: HSEP 01-3.3-01 Internal and External Communication 4. Competency and Training: HSEP 01-3.2-01 Training, Awareness and Competence 5. Asset Integrity: HSEP 01-2.1-01 Hazard Identification and Risk Assessment HSEP 01-3.5-02 Procedure Preparation HSEP 01-3.6-01 Operational Controls 6. Safe Operation: HSEP 01-3.4-01 Employee Involvement HSEP 01-3.6-01 Operational Controls 7. Contractors, Suppliers, and Others: HSEP 01-2.2-01 Legal and Other Requirements HSEP 01-3.3-01 Internal and External Communication HSEP 01-3.4-01 Employee Involvement HSEP 01-4.3-01 Contractors, Suppliers and ID Community 8. Emergency Preparedness: HSEP 01-3.7-01 Emergency Preparedness and Response 9. Incident Reporting and Analysis: HSEP 01-4.2-01 Nonconformance Reporting
Document Responsibility: Manager, Inspection Department Issue Date: 9 August 2010 Next Planned Update: 5 August 2013
HSEP 01-4.2-02 Accident, Incident Reporting and Investigation 10. Community Awareness and Off-the-Job Safety: HSEP 01-2.2-01 Legal and Other Requirements HSEP 01-3.2-01 Training, Awareness and Competence HSEP 01-3.3-01 Internal and External Communication HSEP 01-4.3-01 Contractors, Suppliers and ID Community 11. Continuous Improvement: HSEP 01-4.1-01 Monitoring and Measurement HSEP 01-4.2-01 Nonconformance Reporting HSEP 01-4.2-02 Accident, Incident Reporting and Investigation HSEP 01-4.3-01 Contractors, Suppliers and ID Community HSEP 01-4.4-01 Records and Records Management HSEP 01-4.5-01 Audits HSEP 01-5.0-01 Management Review .