You are on page 1of 21

Kot Addu Power Company Limited

DOC. No:

Behaviour Based Safety System-Fresh Eyes

Implementation Date:


Author/ Prepared By:

Reviewed By:


Signature Waheed Sohail

Muhammad Jamil Capt. Sajjad Mahmood Name

Sr. Manager Operations Name

05-03-2012 Date Contents Agreed By: Authorization For Issue/ Approved By:

05-03-2012 Date



General Manager

Khalid Pervaiz Bajwa Name

Chief Executive Officer

Aftab Mehmood Name

07-03-2012 Date References: Distribution: 1. As per Local Procedure AHR/HR/LP/002-02 Date


1. 2. 3. 4. 5.


5.1 The key components. 5.2 The observation process. 5.3 FE observation schedule 5.4 FE observation Form 5.5 Just and fair culture 5.6 Developing the Observation Procedure 5.7 The Fresh Eyes Observation Process 5.8 Feedback on Fresh Eyes Observations 5.9 Feedback on implementation and Improvement Goals 5.10 The observation form 5.11 Data Management 5.12 Fresh Eye communication 5.13 FE Rewards.





The purpose of Fresh Eyes procedure is to provide a guide for the implementation of a behaviour based safety-BBS process at KAPCO. The objective of Fresh eyes procedure is to enhance the meaningful involvement of all employees in Safety Management System for continuous improvement in Safety Performance as measured by observation data and accident and incident rates. Involvement of embedded contractor staff is essential element of BBS; so management must actively encourage their participation in the process. Controlling unsafe acts at the work place is one of the keys to successful accident prevention; Fresh Eye is a process of observing the people behaviors towards Safety at their work place, giving immediate feedback and keeping observation record for establishing future improvement goals.

Potential Gains from the Fresh Eyes Behaviour Based System-BBS Observation Process
There are several potential benefits of the Fresh Eyes (BBS) observation process. They include the following: Positive reinforcement through the feedback process which eventually, promotes a stronger safety culture. Stimulates conversations among employees about safety. The feedback which employees receive allows the development of a positive safety culture by promotion of safer ways to perform work. Promotes sharing of knowledge among employees, both observed and observers, where they learn to identify hazards in their work areas. Establishes a means for employee ownership and accountability for safety and health. Leads to reduction in accidents and injuries.



The Behavioral Based Safety program applies to KAPCO plant and is part of the site Safety Management System. Contract staff is an integral part of the process. Everyone at site shall be involved step by step in the process of conducting safety observations. This program forms part of the GDF-Suez-International Power safety culture.



The CEO and General Managers shall actively support the Fresh Eyes process by ensuring the necessary resources and through participation in training and observations. All KAPCO employees / Contractors employees shall actively participate in the Fresh eye awareness, training and implementation process to boost the Safety culture at site. Sr. Managers, Managers / Section Heads: To actively participate in support of the implementation and to maintain the Fresh Eyes (BBS) process at all levels. To commit the necessary resources, including management participation and funding for various elements of the process (meetings, training, safety awards, etc.). To identify the asset Fresh Eyes BBS Co-ordinator(s). To participate in the Fresh Eyes observation process. To participate in the management review process. To nominate employees from their work area as Observers.

The Fresh Eyes Coordinator Coordinates all aspects of Fresh eye including, To review Fresh Eyes BBS training to achieve an understanding of the Fresh Eyes BBS process. To review Asset specific Fresh Eyes observation forms and procedures based on the unique needs of the individual asset. To develop a feedback system. To schedule routine observations and ensure implementation as per plan. To review observation data and report statistical analysis of observed data. To participate in the management review and Safety Forum meetings and giving recommendations. To train asset Fresh Eyes observers how to conduct an observation. Chairing the Fresh Eyes committee and observer meeting. 3- Monthly feedback meetings shall be scheduled. Minutes recorded and action done in a timely manner. Inputting data into the IPR Live Link (FEDA System). To coordinate GDF-Suez-International Power Global Safety Steering Group for Feedback on Fresh eye implementation at site.

The Fresh Eyes Committee Fresh Eyes BBS Committee consists of at least one Management Team member and an asset Health and Safety Committee member. In addition, two to five staff members across the Complex and representation from permanent contractors will also be included in the committee.

Responsibilities include assisting the asset Fresh Eyes Coordinator in the implementation of the Fresh Eyes BBS process. To develop Asset specific Fresh Eyes observation forms based on the past Safety reports. The FE Committee may change the asset specific observation Form when it considers it to be appropriate. To develop a detailed implementation plan including awareness sessions, Observers Training schedules and FE Observation schedules. To develop a feedback system. To provide guidance and ensure continued progress of the behavioral safety process.

The meeting is convened by the coordinator quarterly or on needs basis. Awareness training for the committee as well as the observers on a regular basis is advised so as to counteract the question what is Fresh Eyes? The Observers For every 10 employees it is recommended that there should be one observer. The Observer role will eventually rotate through all personnel at the work place. Moreover all employees are authorized (and obligated) to stop serious unsafe acts at site immediately. The enthusiastic persons having capacity to learn and who can confidently discuss safety issues with the Work party would prove to be effective members in the first step of implementation process. It is however not necessary for an observer to be a safety expert. Observers will complete the fresh eye BBS training and become proficient observers. Observer and the Observed may be from the same peer group or a mix of employees at all levels. They will carry out regular observations as per schedule and return the feedback forms to FE coordinator. 3-monthly observers meeting should be ensured which would produce synergy and help to discuss the common issues and any further improvement actions. Observers use Fresh eye LOGO in the form of badges or jacket during observation process and they can visit any work place at plant area without restriction and prior permission. Observers must concentrate on the quality of feedback given during the observation process. One observation shall be provided by two observers for every ten employees, once per month. e.g. If KAPCO has 600 regular staff and contractors have 300 staff to give a total of 900 staff, then in principle there shall be, 90 observations record at minimum per month.

A proactive safety management approach that motivates individuals to demonstrate safe behaviors by engaging with them to continually improve. The approach uses the techniques of regular peer-based observation, peer feedback on performance, rewarding positive behavior, target setting and consistently managing safety in a just and fair way.

Behavioral Based Safety


The beliefs and attitudes that the people in a particular group or organization share.


Self-satisfaction especially when accompanied by unawareness of actual dangers or deficiencies. In this context the fear of injury that motivates employees to work safely is lost.


Anything which precedes and triggers behavior.


The way a person functions in a particular situation. Behavior is an observable act that is measurable.


Anything which directly follows from behavior

Fresh Eyes Observations

The systematic and planned observation of people to verify that work is performed efficiently and in compliance with HSE standards

Feedback The process of communicating and reviewing observation Data. Attitude A person's perspective toward a specified target and way of saying and doing things.


Fresh eyes Procedure Details

The Fresh Eye process is established in accordance to IPR Procedure IPR/H&S/PRC/026 and details as given bellow.

Fresh Eye coordinator is responsible for the implementation of the whole system with the help of Fresh eye Committee supported by Management.

5.1 The key components.

The key components of the Fresh Eyes process are: 1. A peer-on- peer behavioral observation process provides data that can be used to measure on-the-job safety 2. Feedback process for communicating and reviewing observation data 3. Development of improvement goals 4. Recognition for improvement and goal achievement The process initially involves the identification of safe behaviors, or desired behaviors (from data of past injuries or safety reports) that would reduce the likelihood of incidents. The next stage involves setting up an observation process that provides feedback and data regarding those behaviors. The observation data is reviewed and analyzed. Improvement goals are established. Achieved goals are recognized by a reward scheme. The feedback process is a critical element in the success of Fresh Eyes BBS. One very important concept of behavioral safety is a just and fair culture. It is equally important to recognize safe behaviors and commend them, as it is to note the unsafe behaviors and point them out for improvement.

5.2 The observation process.

The foundation for maximizing the effectiveness of the Fresh Eyes BBS process is the regular observation of safe and unsafe practices. An effective observation process results in the following: Improves hazard recognition, revealing unsafe practices that, if not corrected, will eventually result in accidents. Provides continuous feedback on the progress of the behavioral program and the attainment of improvement goals.

5.3 Fresh Eye Observation Schedule

Scheduling of observations is based on attached Observation Schedule, which spreads the observations evenly across the work force and plant areas. During normal plant operations, the Observer group can seek guidance from the Planning Department to determine where the work is planned to observe a working party. The Fresh Eyes Coordinator schedules the observations. He also manages any queries in relation to the process. During outages, the observation frequency should be 3 times more than normal routine.

Committee members manage the Observers from within their own areas of responsibility.

5.4 Fresh Eye observation Form development Process

Observation checklists have been developed using past injury, incident and near miss data, including critical safe practices. (e.g. PPEs and hand tools). Four generic categories form the checklist plus a fifth, which the committee can vary if appropriate. Check list categories. 1.Personal Protective Equipment (PPE) 2.Housekeeping 3.Risk Management 4.Tools and Equipment 5.Ergonomics / Body position Observations and Feedback Fresh Eyes observations are undertaken by trained personnel who can confidently discuss safety issues with the Work party. It is however not necessary to be a safety expert be an observer. For achieving better results of Fresh Eyes BBS, Observers must concentrate on the quality of feedback.

5.5 Just and fair culture

To ensure the successful adoption of the behavioral program everyone will need to develop trust in it. To enable this, the Fresh Eyes Safe Work Observation process must be applied as just and fair culture. In practical terms, for employees to trust the Fresh Eyes program, the observation sheets completed by observers must be untraceable to the observed employee; therefore during any observer training it should be stressed that the name of the individual should not be recorded. Just and fair culture should also reflect during formation of Fresh Eyes committee and Observers team, Observation schedule and implementation process. Representation of employees from all areas should be ensured in an evenly manner.

5.6 Development and Review of Observation Procedure

The following should be determined and documented for developing Fresh Eyes observation procedure: Observers shall be trained and their names documented. Observers should conduct the observations in a regular and scheduled manner coordinated by FE coordinator. Contract staff should be integrated into the process by their representation in Fresh Eyes committee and as observers as well. checklists from will be available in CCRs and share drive; the observers will return completed observations to Fresh Eyes Coordinator.

5.7 The Fresh Eyes Observation Process


The foundation for maximizing the effectiveness of FE is the regular observation of working practices. The benefit of an observation process is that employees learn to work more safely. In addition, by undertaking safety observations, employees learn to identify hazards in their work areas. Paying attention to the process means paying attention to safe practices. The frequency of BBS observations are determined by the particular risks involved. The greater the risk, the more frequent the observations should be.

5.8 Feedback on Fresh Eyes Observations

Observers should provide immediate feedback as part of their observations. When giving feedback, a three-step feedback process works equally well for both positive and corrective feedback: 1. Describe the behavior observed 2. Discuss the potential impact on the employee and co-workers 3. Listen what the employee has to say and then, for corrective feedback, make a specific suggestion that pinpoints what he or she should be doing differently. A good observer asks and enquires before telling and instructing. When unsafe situations are identified, all employees are authorized and obliged to stop the unsafe acts and aid in their prevention. The situation must be brought to the attention of the relevant person(s). Unsafe act / unsafe condition, or Near miss reporting by every employee is already a part of the existing safety Management system and fresh eye is not a substitute for them.

5.9 Feedback on implementation and Improvement Goals

The responsibility for setting the feedback process and improvement target should be with the Fresh Eyes coordinator and asset Fresh Eyes Committee. Forms are attached for keeping and tracking Fresh eye implementation record.

5.10 The observation Form- KAPCO (Annexure F02)

Each form comes with an explanation page. Observers are encouraged to use it as a guideline. The observation forms should remain anonymous. One observation is to be provided by two observers for every ten employees, once per month. If KAPCO has 600 regular staff and contractors have 300 staff to give a total of 900 staff, then in principle there shall be, 90 observations record at minimum per month.

5.11 Fresh Eye Data Management

FEDA (Fresh Eyes Data Analysis), database software is maintained at local server of IT network, while the Fresh Eyes Live Link database software is available at Global International Power GDF-Suez network to record all Observation data. Trending and reviewing of data is undertaken once every month to help prevent the reoccurrence of unsafe incidents, events and behaviors. The Coordinator as well as the committee identify trends by using FEDA. This allows for

variations with the individual observer skills and experience to work through. The Fresh Eyes Coordinator will also ensure that the following requirements are being fulfilled: Fresh Eyes observation data entering and analysis at the asset Uploading of Monthly asset data to Global database through FEDA Live Link. Also report any unusual, inconsistent FEDA Link trends to the Global Safety Steering Group / Safety Committee. Once every month, display graphically the Fresh Eyes statistical data on the Safety Notice boards. - IT section will ensure proper functioning of Fresh Eye Data Base FEDA and will support Fresh Eyes coordinator to carry out all the above activities and functions regularly and in a smooth manner.

5.13 FE Rewards and recognitions.

Each Year Fresh Eyes Committee will recommend staff for safety rewards and recognition which are based on behaviors that promote safety, such as - Excellence in conducting observations. (Champion of the month) - Excellence in maintaining a safe work place as measured by observation data. (Fresh Eyes Safe Work award) The safety award process provides a way of celebrating successes and expressing appreciation to employees who work safely as well as those who make exceptional contributions. Safety awards should be kept small.


6. FORMS AND ATTACHEMENTS List of Applicable Documents

REFERENCE IPR/H&S/PRC/026 H&S/PRN/026 ENG/KBOPS/SAF/LP/032-F01 ENG/KBOPS/SAF/LP/032-F02 ENG/KBOPS/SAF/LP/032-F03 ENG/KBOPS/SAF/LP/032-F04 ENG/KBOPS/SAF/LP/032-A01 ENG/KBOPS/SAF/LP/032-A02 ENG/KBOPS/SAF/LP/032-A03 ENG/KBOPS/SAF/LP/032-A04 ENG/KBOPS/SAF/LP/032-A05 ENG/KBOPS/SAF/LP/032-A06 DESCRIPTION Behavioural Based Safety document (from GDF-Suez-IP) Operations and Engineering Principal H&S. Behavior Based Safety document Observation Form_ Urdu v1.doc Observation Form_ English v1.doc (Plant /offices) Observation Schedule.xls Fresh Eyes observation status.xls Fresh Eyes Logo .pdf Fresh Eyes awareness course_english.ppt Fresh Eyes observer course_Urdu.ppt Fresh Eyes observer course_english.ppt.ppt Fresh Eyes management course.ppt Fresh Eyes Brochure_ English .pdf

ENG/KBOPS/SAF/LP/032- A07 Fresh Eyes Brochure_ Urdu .pdf ENG/KBOPS/SAF/LP/032-A08 ENG/KBOPS/SAF/LP/032-A09 Video. FE for the renewed guy_ English Video. FE for the renewed guy_ Urdu

The following International Power Safety procedures can be obtained from Fresh Eyes coordinator /Safety department / web portal
IPR/H&S/PRC/026 H&S/PRN/026 Behavioural Based Safety document (from GDF-Suez-IP) Operations and Engineering Principal H&S. Behavior Based Safety document 11

Form- F02 (Page 1 of 2)

Fresh Eyes Observation Notes (Plant)

Observation ID Number Observers : People Observed:
Plant Area:

Task: No. of safe No. of at-risk


Observation Results:

Action taken/ Feedback given

Comments (Do not record names)

1.00 PPE are individuals wearing appropriate: 1.01 Are individuals wearing safety footwear? 1.02 Eye protection using when required? (goggles, shield) 1.03 Wearing hard hats or other head protection 1.04 using hearing protection when required? (ear muff, Plug) 1.05 Gloves use as required during the job? (insulated, cotton) 1.06 Other PPE for task e.g. mask, respirator, Face Shield? 1.07 Is the PPE in good condition? Worn shoes, gloves insulation 2.00 Housekeeping 2.01 waste products or materials being disposed off correctly? e.g Cotton rags, debris, empty drums, pipes, consumables. 2.02 Hazardous material stored/labelled correct, e.g. chemicals, thinners, toxics, lubricants, gas cylinders tied? 2.03 Work area free of slip/trip hazards, e.g. hoses, wires, tools? 2.04 Is appropriate fire and emergency equipment in place? (CO2 cylinder, Fire blanket, Hose pipes, etc) 2.05 Is there safe access to enter and way out? (any restriction) 2.06 Is there adequate lighting for the task? (48V confined space) 2.07 Are hazardous conditions barricaded? (Tape, Fencing, signs) 2.08 Are materials stored and stacked safely? 2.09 Vehicle hazard present and appropriate action taken? 3.00 Risk Management 3.01 Plant and equipment correctly isolated and Tagged? 3.02 Safe work procedures e.g permits, Safe clearances, LOTO, Earthing, Hot work, Excavation, Fire impairment adopted? 3.03 Point of work risk assessment carried out, e.g. Take 5? 3.04 Have they considered the effect of their work on others?


Observation Results: 3.05 working on correct item of plant? (Plant identification ) 3.06 If work scope has changed, have RA & isolation, reviewed? 4.00 Tools and Equipment 4.01 Portable electrical equipment in good condition? (Electric plugs, cables, electric boards, 48V in confined space.) 4.02 Are individuals using compressed air tools safely? 4.03 Hand tools using correctly? (wrench, insulated plair) 4.04 Equipment guards in place? (Fan cover, coupling guard) 4.05 vehicles /mobile equip used correctly? Cranes / Fork lifter 5.00 Ergonomic/ Body Position 5.01 Load need to be manually lifted or can a machine be used? 5.02 Are individuals lifting loads safely? Lifting method 5.03 Are individuals carrying loads safely? 5.04 Are they doing pushing or pulling operations safely?

No. of safe

No. of at-risk

Action taken/ Feedback given

Comments (Do not record names)

Optional categories to be used if appropriate to the task

6.00 Working at Heights 6.01 Does work have to be done at height or can be avoided? 6.02 Is the safest means of access used to approach or work? 6.03 Are they working safely from a scaffold? (Scaff tag OK) 6.04 working safely using a cherry picker or scissor lift? 6.05 Are working safely from a ladder? Ladder condition, Ground fixing, Top fixing, Rungs conditions OK, 6.06 Are they using fall protection safely where appropriate? 6.07 Have considered the effect on workers below? 6.08 Is there a plan for emergency or rescue if incident occurs? 7.00 Lifting Operations 7.01 Is the crane/lifting equip calibration /inspection in date? 7.02 Is the crane/lifting equipment in good condition? 7.03 7.05 Is access within the vicinity of load lift minimised? Crane set level & outriggers positioned on suitably ground? 7.04 Are individuals well clear of any suspended loads? 7.06 If required, are tag lines used to prevent load swinging? 8.00 Site Transport 8.01 Are vehicles & pedestrians adequately separated? Foot path 8.02 Are associated hazards adequately identified & controlled 8.03 8.05 Are vehicles avoiding any vulnerable areas? Road condition Are traffic rules and signage adhered to? Speed limits etc 8.04 Are all vehicle loads secured? Load Length , height, Tied up 8.06 Have vehicle pre-start checks been completed? 8.07 Are drivers licensed and competent?

Recognition or concerns: 13

Entered into Database (FE Observer) Signature or initials

Entered into FEDA (FE Coordinator) Signature or initials

Please forward a hard copy of this form to FE coordinator after it has been entered into the FE Database.

Form- F02 offices (Page 1 of 1)

Fresh Eyes Observation Notes (offices)

Observation ID Number Observers :
No of people Observed: Date: Time:



Observation Results 1.00 1.01 1.02 2.00 2.01 2.02 2.03 2.04 2.05 2.06 3.00 3.01 4.00 4.01 4.02 4.03 4.04 5.00 5.01 5.02 5.03 PPE Appropriate Footwear Appropriate clothing & items Housekeeping Waste products/ materials disposed of correctly Materials Stored &/or Stacked appropriately Effective workstation layout for function Walking surfaces free from Trip Hazards Is there safe access and egress Is there adequate lighting for the task at hand Risk Management Effect of their Work on Others Tools and Equipment Chair adjusted for best fit Electrical Equipment in good condition Environmental factors assessed & controlled Equipment assessed to be in good working order Ergonomic/ Body Position Work tasks varied to encourage posture changes Individuals lifting / moving loads Safely Manual handling tasks assessed & controlled

No. of safe

No. of at-risk

Action taken / Feedback given

Comments (Do not record names)

Recognition or concerns:

Entered into Database -

Entered into FEDA -


(FE Observer)

Signature or initials

(FE Coordinator)

Signature or initials

Please forward a hard copy of this form to Fresh Eye coordinator after it has been entered into the Fresh eyes Database.

Form F03

Fresh Eye observation schedule (to be modified as per requirement, Rotated &
announced every Month by FE- Coordinator)

Day / Team / Week

Tuesday SM- HR/Fin/Proc

Gas turbine 5-8 Machine hall / Filter house / Injection skid / Gas skid / HRSG11A,B,12A,12B STG11-12 machine Hall, 11KV/ 380V Switch gear room, Machine hall / Feed water Building STG11-12

Wednesday SMM-Block-1
Gas turbine 13-14 Machine hall / Filter house / Injection skid / Gas skid / HRSG1314 STG15 machine Hall, 11KV/ 380V Switch gear room / Machine hall, Feed water building STG15

SMO- Team
Gas turbine 1-4 Machine hall / Filter house / Injection skid / Gas skid / HRSG1-4 STG9-10, 11KV/ 380V Switch gear room, Machine hall, Cooling tower area / cooling tower switch gear room

Thrusday SMM-Block2
FOTP-1,2,3,4,5, Auxilliary steam Boilers

Friday SMM-Block3
Stores A,B,C,D,E,F, G / Kanteen



Block-1Demi plant / Chlorine plant /Chemical laboratory/ Block-1 Workshops (Elect / Mech/ I&C

Block-2 Demi plant / clarifiers / Cooling Towers STG11-12

Block-3 Demi plant / Chlorine plant /Cooling Tower STG15

Thermal Oil heaters 5-8, Thermal Oil heater 13-14/ Forwarding Skid 1314/Forwarding skid 5-8 Fuel Oil tank areas Tank 1-27

Shift Operations Morning / Evening - routine round - Isolation /deisolations process FOTP / Chemical Shift Operations - routine round - Isolation / Deisolation process Offices / Labs CCR-1,2,3 Ground floor/ 1st Floor/2nd Floor /Offices Admin Building / ARE building / Fuel workshops

132KV Switchyards/ Fire Fighting Staion/ Main Mechanical/ Electrical workshop

Block-2 Workshops (Electrical / Mech/ I&C / 220 KV Switchyards

Block-3 Workshops (Electrical / Mech/ I&C/ Store-G / Gas station /220 KV Switchyard

FOTP-Oil Decanting station &



Observers List (Nov 2011)

Block-1 Observer Mech Electrical I&C Block-2 Observer Mech Electrical I&C Block-3 Observer Mech Electrical I&C Operations Observer Fuel Shift Ops Chemical / others Manager (HR/Finance/Procurement) Observer HR Finance

Contractors Staff Observer Services Security





Fresh Eyes
Asset Management Team Behavioural Based Safety (BBS)



KAPCO Asset Coordinator Committee

IPR CONCEPT: Safety Related Activities Behaviour of People change to BBS

Regular FE Observation & Periodic FE Audits and Reviews and regular report

FE Super Trainer & Asset Trainers


FE Observer

FE Observer

FE Observer

FE Observer

FE Observer

FE Observer

FE Observer

FE Observer


FE Observer

FE Observer

Rev:0 01/10/11



Fresh Eyes observation status.xls

Sample format for Fresh eyes Observations Feedback Process

Fresh Eye observations Plan /Actual
130 120 110 100

No. of Observations

90 80 70 60 50 40 30 20 10 0 Plan Actual


Ju ne

Ju ly A ug us t S ep

Fe b

ar ch

Ja n

ov N






Fresh Eye observations %Safe Behaviours

100 90 80

No. of Observations

70 60 50 40 30 20 10 0 % avg Safe behav No. of observations

Fe M b ar ch A pr M ay Ju ne Ju A ly ug us t S ep


Fresh Eyes Logo .pdf

O ct N ov D ec

Ja n



Fresh Eyes Brochure_ English .pdf

Updated Forms, presentations and video of the following documents are available with Fresh eye co-coordinator / Safety coordinator and on Safety portal at Share drive.

Fresh Eyes awareness course_english.ppt Fresh Eyes observer course_Urdu.ppt Fresh Eyes observer course_english.ppt.ppt Fresh Eyes management course.ppt Video. FE for the renewed guy_ English Video. FE for the renewed guy_ Urdu

The following documents in Urdu language can be delivered to enhance communication at Staff level.



Observation Form_ Urdu v1.doc


Fresh Eyes Brochure_ Urdu .pdf


Video. FE for the renewed guy_ Urdu