Management Systems in Production Engineering

2012,No4(8),pp1924

ANALYSISOFSAFETYATWORKRATEINCHOSENMINESOFUPPERSILESIANCOALBASIN
KrzysztofKURUS SilesianUniversityofTechnology BarbaraBIAECKA CentralMiningIns tute

Abstract: Thear clepresentsanexperimentalcomparisonofsafetyatworkinhardcoalmineslocatedinUpperSilesiaCoalBasin. Theaimwastoshowthebestprac cesandac vi esinPolandandCzechRepublicwhichcouldbesuccessfullyimple mentedinotherminesinordertoimprovesafetyoftheirworkers.

Keywords:mining,safety,accidents,CzechRepublic,mines

INTRODUCTION The mining industry keeps focus on con nuous im provement of safety at work as well as introducing new ac vi estoachieveit.Theeciencyoftheseac vi escan beraisedifthesafetymanagementsystemisimplemented. Therightmanagementisthebestwaytokeepthesa sfac tory level of health and safety at work which is crucial ma erduetorulesoflaw,socialresponsibilityandoppor tunitytoreducethecostsofextraordinaryevents[10]. Safety at the workplace and responsible behavior of employees are not a coincidence. Safety should be devel opedaccordingtoaprogramcreatedinadvancebyanor ganiza on. The program could be nonformalized or for malizedbasedonnormPNN18001(OHSAS)whichisone ofthemostusefultoolofimprovementofworkquality. Thear cleincludesasafetyatworkanalysisofchosen coalmines.Theobjectsofcomparisonweretwocoalcom

panieslocatedinUpperSilesiaCoalBasinonePolishand oneCzech(g.1.)[3]. Thesafetyatworkinminingdependsongeologicalcon di onsofadeposit,amountofextrac onanditsintensity, technology,legalsystemandawarenessofworkers.[3]Due tothesimilarityofgeologyandtechnology,themineslocal izedinUpperSilesianCoalBasintheanalysisseemstobe jus ed. Publica on includes not only the compara ve analysis ofsafetycondi onsbutalsosomesolu onswhichcouldbe implementedinothercountries. SAFETYATWORKINCOALMININGINDUSTRY Undergroundcoalextrac oninUpperSilesiaischarac terizedbyseveregeologicalcondi onswiththepresenceof almostallknownnaturaldangersrecognizedintheworlds mining. The technical, organiza onal, workenvironmental condi onsandthreatsaretendtogetworseeveryyear.

Fig.1.CurrentcoaleldsofJSWandOKD[3] Legend:horizontalstripesminingeldsofJSW,nr15minesofJSW,diagonalstripesminingeldsofOKD,nr610minesofOKD

20ManagementSystemsinProduc onEngineering4(8)/2012 K.KURUS,B.BIAECKAAnalysisofsafetyatworkrateinchosenminesofuppersilesiancoalbasin

Table1 Mainthreatscausingthemostinjuriesinundergroundmines[2,6]
Natural rockbursts, explosionsandinamma onsofgasanddusts, outburstsofgasandrocks oodandquicksand, res, stayinginatoxicatmosphere. Technical contactwithworkingmachinesanddevices, detona onofexplosives, failureofpressuredevices, contactwithhotfactoranddangeroussubstance, contactwithlivemachines,devices,wires Personal downfall,stumble,fallingover, accidentalcontactwithanotherworker (par cipantinthetechnologicalprocess)

Themainfactorsinuencingoncurrentsafetyinmines ofSouthernpartofUpperSilesianCoalBasinare: 1)far advanced level of deposit extrac on which has loweredthecruststability, 2)high and quickly raising mining depth (circa 58 me tersayear), 3)exploita on of mul seam deposits (edges, rests andpillars), 4)commonunderlevelseamexploita on(moredi cultandinecientven la on), 5)longterm negligence in equal and sucient invest mentofminingindustry, 6)popularity of outsourcing in underground works [6, 8]. The table 1 includes the main threats causing the big gest amount of injuries in Polish and Czech coal mines in the last 6 years. The table was created according to the reportsofWyszyUrzdGrniczyandSttnBskSprva PolishandCzechstateminingindustryauthori es.

PRESENTATIONOFANALYZEDCOMPANIES Theobjectofcompara veanalysiswere2chosenhard coalproducersopera nginUpperSilesianCoalBasin(pic. g. 2): Jastrzbska Spka Wglowa Ostravsko Karvinsk Doly. The tables 24 include basic compara ve data which characterizethecompanies.Thetable4referstotheactsof mininglawinPolandandCzechRepublic. Thedatainthetableindicatetheclosesimilarityofboth companies.JSWandOKDemploy22700and18000workers (dierence20%),theyproducealmostthesameamountof hardcoal(dierence16%).Thecompaniesextractcoalonly inundergroundmines. The produc on volume of two companies seems to be verysimilar.Duetoreduc onofdemandonglobalmarkets JSWandOKDdecidedtodecreasetheirextrac oninmines. Thebothcoalcompaniesmakethemostprotsfromselling cokingcoal.

Fig.2.Coalproduc onofJSWandOKD[1,4] Table2 Analyzedcoalcompanies:JSWandOKD

Companyname Country Numberofac vecollieries Totalemployment Coalproduc on[mlnMg] Averagedepthofexploita on[m] JSW Poland 5 22700 12.6 850 OKD CzechRepublic 4 18000 10.6 930

Table3 Thecollieriesofanalyzedcompanies,datafrom2010[1,4]indicatednumberonthemaprefertog.1
JastrzbskaSpkaWglowa Numberonmap Collieryname Annualproduc on,[mlnMg] Reserves,[mlnMg] Numberonmap Collieryname Annualproduc on,[mlnMg] Reserves,[mlnMg] 4 BoryniaZowka 3.87 100 9,10 Karvin 4.1 89 2 Budryk 3.06 236,5 6 SM 2.9 45 5 JasMos 1.59 30 7,8 Darkov 3.2 37 1 Krupiski 2.19 60,3 11 Paskov 1.0 24 3 Pniwek 2.62 88,5

OstravskoKarvinskDoly

ManagementSystemsinProduc onEngineering4(8)/201221
K.KURUS,B.BIAECKAAnalysisofsafetyatworkrateinchosenminesofuppersilesiancoalbasin Table4 ComparisonofcurrentPolishandCzechminingsafetyregula ons
JSW Ustawazdnia9czerwca2011r.Prawogeologiczneigrnicze (Miningandgeologyact) (2011/163/981) Ustawazdnia26czerwca1974r.Kodekspracy(1974/24/141) (Labourcode) RozporzdzenieMinistraGospodarki zdnia28czerwca2002r. wsprawiebezpieczestwaihigienypracy,prowadzeniaruchuoraz specjalistycznegozabezpieczeniaprzeciwpoarowegowpodziemnych zakadachgrniczych (H&Satworkinmines,conduc ngtheminingenterprise,under groundreprotec onact) OKD ZkonNR.61/1988Sb.,ohornickinnos ,vbuninchaosttnbsk sprv (Miningac vity,explosivesandminingstateauthorityact) Zkon.262/2006Sb.,zkonkprace (Labourcode) VyhlkaB.22/1989Sb., obezpenos aochranzdravpiprci abezpenos provozupihornickinnos apidobvnnevyhrazench nerostvpodzem (H&Satworkinmines,conduc ngtheminingenterpriseandotherworks underground)

RESEARCHMETHODOLOGY Theevalua onofsafetyatworkintheenterpriseswas conductedusingtheexternalbenchmarkingmethodwhich consistsofcomparisonofsomeac vity[5].Comparingthe twocompaniesisarightwaytondthebestprac cesand latertoimplementthem. Justi ication of comparison Thereisnouniversalmethodtocheckifthebenchmark ingconduc onisjus edandusefulinindica onandsolv ingaproblem.Choosingtheobjectofcompara veanalysis hadbeenprecededbyapreliminaryrecogni onthatprove enough number of features between the companies to chooseabenchmarking. Thetablebelowcontainscriteriabywhichitwasconsid eredthatcomparisoncouldbecarriedoutandbringsome benets.
Table5 Compara vecriteriaoftwocoalcompanies(ownstudy)
Criterion Produc onvolume Formofmining Seamcharakteris cs Employmentlevel Loca on Legalsystem Descrip on Similarproduc onandinvestmentopportuni es Thesamenaturalcondi onsaswellaschosen extrac onform Ali ledierenceinemployment;thenumber ofpredictedaccidentsshouldbeatleastsimilar Comparableleveloftechnicaldevelopment Legalregula onsinminingarealmostthesame intwocountries

It is good to men on that the both mining companies are characterized by dierent tradi on, organiza onal cul tureandawarenessofemployees(tab.6).
Table6 Criteriawhichdieren atetwochosencoalcompanies(own study)

CoalmininginCzechRepublichasgotalocalcharacter anditisnotconsideredasaleadingbranchofeconomy.
Criteria Tradi on JSW Aliveawarenesselement inUpperSilesia.Miningas abasicbranchofeconomy OKD Miningasabranchofecono my

Awareness

CreatedbyIntegrated ManagementSystem

Con nuouscrea ngthe knowledgeandawarenesss inmanyways

JSW and OKD had chosen dierent ways to improve safetyintheircollieries:JSWbelievesthatIntegratedMan agement System is the best tool to achieve be er results, OKD not only uses the system ac vi es but also other meanstoencourageitsemployeestoworksafer. Research methodology The research was undergone according to the diagram (g.3).

Problem selection

JSW

Evaluation

Choice of comparison criteria

Comparison of: law, tradition, awareness, technology, organisational culture

Selection of companies

OKD

Best practicies

Fig.3.Comparisondiagramofthetwocompanies

22ManagementSystemsinProduc onEngineering4(8)/2012 K.KURUS,B.BIAECKAAnalysisofsafetyatworkrateinchosenminesofuppersilesiancoalbasin Methodologyofresearchincludedcri calevalua onof the data shared by the companies as well as analysis of widely accessible materials available in the internet. The carriedoutresearchreferstothe6yearsofcompaniesac vity.Thelengthoftheanalyzedperiodseemstoallowto getaprovenevalua on. There were 4 analyzed indicators of safety at work in JSWandOKD: LTIFR Lost Time Injury Frequency Rate the num berofconrmedaccidentsatworkdividedbyamil lionworkhours, AccidentratepermillionextractedMgofcoal, Accidentrateper1000employeesayear, FatalaccidentratepermillionextractedMgofcoal. PRESENTATIONOFRESEARCHRESULTS LTIFR The number of conrmed accidents per million work hoursinthecompaniesarepresentedintheg.4[9]. In20052010wecanseeagreatimprovementinsafety levelinOKD,inthisperiodtheratedecreasedbelow10.In JSW the accident rate is constant (LTIFR around 11), the lackofposi vechangesforcesthecompanytoconsiderthe needofbuildingabe erawarenessinsafetyatwork. At the end of 2010 the companies were at the similar levelofsafetyatwork.FurthermoreOKDaccidentsta s cs includealsoeventsthathappenedtotheoutsourcingwork ers[1,4]. Accident rate per million extracted Mg of coal Thegure5presentsthedatafromallPolishandCzech coalminingfacili es.Thediagramreferstotheallaccidents happenedintheminesregardlessofplaceofemployment. In Polish collieries there are no signicant changes in accidentrate.Between2005and2008theindicatorshows evenagrowingnumberofaccidentspervolumeofextract edcoal. TheCzechminesmanagertoreducetheratefrom70to below30(20052010),whatshouldbeconsideredasasuc cess[2,6]. Accident rate per 1000 employees a year Thediagramcontainsonlyaccidentsthathappenedonly totheworkersofJSWandOKD(g.6). Theratehasbeensuccessfullydecreasedinyears2006 2010 in OKD. At the begging of the period about 45 from 1000hadbeeninjuredatworkannually,in2010thenum berwasabout17.AccidentrateforJSWinyears20052010 uctuated around 16 and 19 with no signicant annual changes[1,4]. Fatal accident rate per million extracted Mg of coal. Thediagram(g.7)referstoallfatalaccidentsthathap pened in mines of both companies regardless of place of employment. The presented diagram does neither show any signi cant trends inthe eldof safety. It is veryhard to explain whythetrendsareequalinallresearchedyears.Theaver age rate of fatal accidents in both companies was almost thesame[2,6]:JSW=0.34;OKD=0.35

Fig.4.LTIFRinanalyzedcompanies

Fig.5.AccidentratepermillionextractedMgofcoalinOKDandPolishmines

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K.KURUS,B.BIAECKAAnalysisofsafetyatworkrateinchosenminesofuppersilesiancoalbasin

Fig.6.Accidentrateper1000employeesayear

Fig.7.FatalaccidentratepermillionextractedMgofcoal

RESULTSANDCONCLUSIONS Therearemanyindicatorswhicharehelpfultoevaluate ac vity of mining industry. The eciency of a par cular minecanbeprovenby:unitcostofcoalextrac onandpro cessing, average quality product parameters or nancial resultsofcompany. Thesafetyatworkrateisanothertypeofanindicator. Keepingthehighlevelofhealthandsafetycontributesto: reduc on of costs caused by the accidents (interrup on,rescueac on,casestudy), ecientproduc onplanning, posi veexternalandinternalmarke ngeects. Carriedoutcompara veanalysishasproven: close similarity of both enterprises in: produc on, employment,numberoffacili esandorganiza on, thesignicantimprovementofsafetyinOKD, constantaccidentratesinPolishmining, almostiden calfatalaccidentfrequencyrateinboth companies, similar, current safety level in two companies (beginningof2011), agreatdierencesbetweenwaysofcrea ngaware nessofemployees. Theresultsoftheanalysisarefollowingconclusions: Hard coal mining industry is characterized by a high accidentrate(amountofaccidentsper1000workers annually).Thereasonofthisfactisprobablyprimary risk caused by the underground mininggeological condi ons. The main elements of risk are natural, technicalandpersonaldangers. Reduc onofthreatsassociatedwithaccidentrateis realized by safety regula ons and principles related

to preven ons, deterring the natural and technical dangers.Itisalsogoodtomen onthatwideexperi enceofpersonnelandtechnologycanalsoprovidea saferworkcondi ons. In 2004 JSW implemented management system of healthandsafetyatwork.Theintroduc onwascar ried out with reali es taken into account breaking theexis ngbarriersandtradi onsaec ngthesafe tylevel.Itusedtobeacommonproblemthatsafety in mining was only associated with the condi on of equipment and human capabili es. The deciding in uence on crea ng the accident rate relies on knowledgeofemployeesandfrequencyoftheirirre sponsiblebehavior.TheconstantaccidentrateinJSW forces to take into considera on ac vi es to form a be er awareness of workers and their par cipa on increa ngsafetyculture. OKDinresearchedperiodwastendtoreduceitsacci dentrate.Itmayprovetheeciencyofimplemented systemac vi esinsafetyatwork.Themanagement declarealltheprocessesperformerundergroundand on surface must fulll all the safety regula ons. The companyisgoingtoeliminateallthethreatsandnui sance.Theaimcanbeachievedwiththefullsupport andengagementoftheemployees. Special importance was given in the Czech Republic by workers building a safe working environment for themselvesanpeoplearoundthem.Thesafebehav ior is highly rewarded with material prizes such as cars or trips. The signicant reduc on of accident rate in OKD may be an evidence of correct strategy and can be considered as a best prac ce which is worthofpropaga on.

24ManagementSystemsinProduc onEngineering4(8)/2012 K.KURUS,B.BIAECKAAnalysisofsafetyatworkrateinchosenminesofuppersilesiancoalbasin REFERENCES [1] Prospekt emisyjny Jastrzbskiej Spki Wglowej z 7 czerwca2011roku. [2] Zprva o stavubezpenos v hornictv za rok 2010. RaportSttnbsksprvy.Ostrava2011. [3] SantoriusP.,BiaeckaB.,GrabowskiJ.:rodowiskowei gospodarcze problemy terenw zdegradowanych przez grnictwo w GZW. Grnictwo i rodowisko kwartalnikGIG.Nr1,2007. [4] Vronzprva OKD: 2006, 2007, 2008, 2009, 2010. RaportyrocznespkiOstravskoKarvinskDoly. [5] ChroszczH.:MoliwocizastosowaniaBenchmarkingu wgrnictwie.Wiadomocigrnicze.Nr2,2011. [6] Stan bezpieczestwa i higieny pracy w 2010 roku. RaportWUG.Katowice2011. [7] GabzdylW.,GorolM.:Geologiaibogactwamineralne Grnegolskaiobszarwprzylegych.Wydawnictwo Politechnikilskiej.Gliwice2008. [8] MacekD.:Przepisyprawneizagroeniawgrnictwie. lsk.Katowice2011. [9] Strona internetowa grupy NWR h p:// www.newworldresources.eu/pl/zrownowazony rozwoj/nasiludzie/zdrowieibezpieczenstwo. (09.04.2012r.). [10] MisiuraI.,BiaeckaB.:,Analizawpywuwdroeniasys temuzarzdzaniabezpieczestwemnajakopracyw kopalni. Studia i Materiay Polskiego Stowarzyszenia ZarzdzaniaWiedz.Z.40,2011,s.263273.

mgrin.KrzysztofKurus SilesianUniversityofTechnology FacultyOfOrganisa onAndManagement Ins tuteofProduc onEngineering ul.Roosevelta26,41800Zabrze,POLAND prof.drhab.in.BarbaraBiaecka CentralMiningIns tute pl.Gwarkw1,40166Katowice,POLAND email:b.bialecka@gig.eu

Artyku w polskiej wersji jzykowej dostpny na stronie internetowejczasopisma.

Thear cleinPolishlanguageversionavailableontheweb siteofthejournal