INSTITUTE BRUNO SCHMAELING

CONSULTING GROUP
SCIENTIFIC DIRECTOR PROF. DR. CHRISTIAN CALLO

Innovative Behavioural Safety

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany

The training programme ”Innovative Behaviour Safety®”
is the intellectual property of Institute Bruno Schmäling
Consulting Group, Prof. Dr. Christian Callo/Bruno Schmäling.
All rights reserved.
All rights of transmission and distribution, electronic storage,
transfer and printing, even in exceptional circumstances or in parts,
are reserved. Non-compliance with these guidelines will have legal
consequences.
Working safely

90 % of all accidents at work are connected to

six unconscious ways of behaving. The aim of this
brochure is to support you in working safely and
without accidents.

With best wishes for a safe working environment,

Bruno Schmaeling Prof. Dr. Christian Callo

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 3

 Perception: Seeing and recognising hazards

Interested in safety Not interested

= hazards are seen = hazards are overlooked

Please remember:

1. W
 e only perceive a part of our surroundings.
Our field of vision is limited.
2. W
 here we direct our gaze is a matter of habit.
3. I f we have perceived a hazard this does not mean
that our colleague has also seen it.
4. O
 ur senses register more information than our
brain can process.
5. O
 ur brain only processes information which is
of interest to us.
6. I f we are interested in accident hazards these are
processed and registered by our brain.

4
Consciously looking for 30 seconds for your
hazards = safety own safety

How to work safely:

✔ Divide your working area into several sections.

✔R
 egularly check these sections for hazards
and changes.
✔S
 tand still and gradually scan the area
with your eyes.
✔C
 onsciously look for hazards which could
cause accidents.
✔ I nclude team members/colleagues in this search
for hazards/changes.
✔D
 iscuss the results of these tours with your
colleagues.
 egularly carry out the Safety Observation
✔R
”Perception: Seeing and Recognising Hazards”.

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 5

 Perception: Seeing and recognising hazards
My personal action plan

What do I have to do in order to recognise hazards

safely? (3 measures)
1.

2.

3.

How can I support my colleagues in recognising

hazards safely? (3 measures)
1.

2.

3.

6
Sustainability Check
PERCEPTION
Managers: once a month
Team/Shift every week

Name:
Date:
Area observed:
Hazard Screen:

Immediate actions:

What is really positive?

My/our recommendations:

Observations have been discussed with those concerned.

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 7

 Using optical signals correctly

Using signal colours Wrong use of signal colours

= safety = danger

Please remember:

1. D
 ifferent colours have different signal effects
on us.
2. W
 e register signal colours such as red, orange,
yellow and light-green particularly well.
3. W
 e also notice certain colour combinations
such as red and white and yellow and black
particularly easily.
4. O
 ur gaze is steered in the direction of these
signal colours.
5. W
 e can use signal colours to mark dangerous
places.
6. S
 ignal colours which have been put in the wrong
place can distract us from potential dangers.

8
Using signal colours = safety

How to work safely:

✔C
 heck where it makes sense to place colour
signals.
✔C
 heck whether the colour markings highlight
the actual danger.
✔C
 heck whether colour signals distract from
potential dangers.
✔C
 heck whether there are too many colour signals
which could cause confusion.
✔C
 heck whether use of colour signals is consistent
(e.g. all edges highlighted in yellow and black).
 very six months, carry out the Safety
✔E
Observation ”Using Optical Signals Correctly”.

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 9

 Using optical signals correctly
My personal action plan

How can I use optical signals to highlight hazards?

(3 measures)

1.

2.

3.

What should I definitely avoid when using optical

signals? (3 examples)

1.

2.

3.

10
Sustainability Check
OPTICAL SIGNALS
This check should be carried out
once a year in every department.

Name:
Date:
Area observed:
1. W
 here are warning signs and notices missing?
Where are they difficult to see?
Location What is missing?

2. Where should colour markings be added to highlight

hazards? (Careful: not too many colours!)
Location Optical signal

3. W
 here do colour markings/pictures/signs distract
from hazards and should therefore be removed?
Location Colour markings/pictures/signs

4. Information to:

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 11

 Safe walking

Use of fixation while Distraction while walking

walking = safety = danger

Please remember:

1. We were born with two safety systems which make

sure that we are able to stand and walk safely.
▪O  ur sense of balance
located in our ears makes sure that we don’t
fall over.
▪F  ixation
When we fix our eyes on a certain point our
brain ”calculates” how we can stand safely.
2. W
 hile we are walking we fix our eyes on a
point which we will reach in approx. 3 seconds:
the point of fixation.
3. I f we recognise a spot where we could trip we fix
our eyes on this spot until we have passed it safely.
4. We
 trip if we don’t use or interrupt visual fixation
while walking.
5. Holding the handrail protects us from falling.

12
Using fixation Switching off fixation
= safety = danger

How to work safely:

✔ Look at the path ahead while walking.

✔ Don’t do anything else while walking.
✔ Stand still if distracted.
✔ Don’t distract colleagues while they are walking.
✔ Use the handrail on stairs.
✔L
 ook at the steps in front of you while
climbing stairs.
✔ Make sure that walkways are secure and free.
 egularly carry out the Safety Observation
✔R
”Safe Walking”.

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 13

 Safe walking
My personal action plan

What do I have to do in order to walk safely?

(3 measures)

1.

2.

3.

What do I have to do in order to avoid trips, falls and

knocks in my area? (3 measures)

1.

2.

3.

14
Sustainability Check
SAFE WALKING
Managers: once a month
Supervisors with one or two employees:
every two weeks

Name:
Date:
Area observed:
1. Please observe:

1.1 D
 oes he/she use the
handrail?

1.2 Is he/she distracted

(e.g. by being on the
phone)?
1.3 D
 oes he/she look at
the point of fixation
while walking?
1.4 D
 oes he/she look
at the steps while
on the stairs?

2. My/our recommendations:

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 15

 Hand-eye coordination:
Controlling movements safely

Controlling movements with Distraction while moving

your eyes = safety = danger

Please remember:

1. O
 ur eyes automatically control our movements.
2. W
 e move and reach in the direction of where
we are looking (sensory motor skills).
3. T
 his is why we are able to control our movements
precisely using our eyes.
4. I f our gaze is distracted, however, our movements
go off in the same direction.
5. I f protective equipment is at eye-level and if we
can easily reach it we will use it.
6. I n the dark our eyes always seek the light.
This is why we move in the direction of the light.

16
Controlling movements Distraction while
with your eyes = safety moving = danger

How to work safely:

✔W
 hile working, consciously control your
movements using your eyes.
✔R
 emember that any distraction during manual
tasks poses a real threat.
✔ I n case of disruption stop manual tasks
immediately.
✔ Avoid any distractions during manual tasks.
✔ I f possible, place protective equipment at
eye-level and where people can reach it easily.
✔C
 heck whether a safe path is lit sufficiently
in the dark.
 egularly carry out the Safety Observation
✔R
”Hand-Eye Coordination: Controlling
Movements Safely”.

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 17

 Hand-Eye coordination:
Controlling movements safely
My personal action plan

What do I have to do in order to control my movements

safely? (3 measures)
1.

2.

3.

How can I support my colleagues in controlling their

movements safely? (3 measures)
1.

2.

3.

18
Sustainability Check
CONTROLLING MOVEMENTS SAFELY
Managers: once a month
Supervisors with one or two employees:
every two weeks

Name:
Date:
Task observed:
1. Please observe:
1.1 D
 oes he/she control
their movement using
the eyes?
1.2 Does he/she control
their hand using their
eyes?
1.3 H
 as he/she been
distracted?
1.4 F
 urther
observations

2. My/our recommendations:

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 19

 Avoiding dangerous reflexes

We react to a signal Looking into the hazard

= danger

Please remember:
1. C ertain reactions are triggered by a certain signal.
For example: We automatically hit the brakes
if the brake-lights of the car in front light up.
2. W hile we are working, certain movements are
triggered unconsciously by a signal.
3. Wrongly triggered movements can lead to an
accident if:
▪w  e are looking into a dangerous area while
working.
▪w  e are able to reach into this dangerous area
at the same time.
➔ The eye creates a line of sight into the danger.
➔ Muscles which allow us to reach into the danger
are supplied with energy.
➔ In case of a disruption there is a danger of a
reflex reaction.

20
 If our work is disrupted ➙ STOP: DANGER!

How to work safely:

✔T
 ogether with your colleagues identify those
tasks where you could look and reach into the
hazard at the same time.
✔M
 ake yourself and your colleagues aware
that with these particular tasks there is a
danger of reaching into the hazard.
✔F
 ind out which disruptions could make you
reach into the danger during these tasks.
✔ Remember this disruption as a danger.
✔P
 ractice the right and safe movement for this
situation (away from the hazard).
 egularly carry out the Safety Observation
✔R
”Avoiding dangerous reflexes”.

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 21

 Avoiding dangerous reflexes
My personal action plan

What do I have to do in order to avoid the reflex of

reaching into a hazard? (3 measures)
1.

2.

3.

How can I support my colleagues in avoiding dangerous

reflexes? (3 measures)
1.

2.

3.

22
Sustainability Check
AVOIDING DANGEROUS REFLEXES
Managers: once a month
Supervisors with one or two employees:
every two weeks

Name:
Date:
Area observed:
1. D
 uring which tasks does the colleague look into
a hazard and could reach into it at the same time?
1.
2.
3.
2. Select one of these tasks and discuss it with your
colleagues:
Which "disruption" could What is the right line of
cause us to reach into a focus and movement for
hazard? this disruption?

3. Give a quick explanation of the grip reflex:

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 23

 Safe working behaviour

Act consciously: Think first,

then act = safety

Please remember:

There are two levels in our brain which

control the way we work:

Level 1: Learning mode

(Conscious actions)

▪ This is responsible for new and

unfamiliar tasks
▪ Requires high levels of concentration
▪ Needs a lot of energy
▪ Takes time – we work more slowly
▪ Is prone to disruptions, caused e.g. by stress!

24
Routine mode: Changes are overlooked = danger

Please remember:

There are two levels in our brain which control

the way we work:

Level 2: Routine mode

▪ This is responsible for familiar tasks

▪ Stores processes which we repeat
▪ Requires lower levels of concentration
▪ Needs less energy
▪ Takes less time
▪ Does not recognise changes!

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 25

 Safe working behaviour

Taking time to familiarise

yourself = safety

How to work safely:

✔F
 or new tasks and/or new colleagues:
▪ Proceed step by step and in the right order.
▪ Consider accident hazards and safety
measures from the very beginning.
▪ Together with your colleagues, correct
mistakes as early as possible.

26
 ?

Regularly checking and adapting

routine = safety

How to work safely:

✔F
 or routine tasks/experienced
colleagues:
▪ Regularly check routine tasks for changes.
▪ Regularly check working behaviour during
routine tasks.
▪ Discuss even those tasks which
”anyone can do”.
▪ Ask your colleagues to explain the
individual steps and compare these to
the standard process.

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 27

 Safe working behaviour
My personal action plan

What do I have to do in order to work safely while

carrying out routine tasks? (3 measures)
1.

2.

3.

How can I support my colleagues so that they learn

new tasks correctly and safely? (3 measures)

1.

2.

3.

28
Sustainability Check
SAFE WORKING BEHAVIOUR
Managers: once a month
Supervisors with one or two employees:
every two weeks

Name:
Date:
Task observed:
1. Order of steps in process (quick summary)
Steps Observation
Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

2. My/our recommendations:

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 29

 Methods for avoiding accidents

1. 1. Update routine aktualisieren

Materials Measure
Danger of Correct
Steps tools Task technical
accident behaviour
machines organisational

1.

2.

3.

4.

5.

6.

2. Quick check of routine

Steps Danger Measure

1.

2.

3.

4.

30
IBS Sustainability Training (once a month)

The focus of our consultancy and training work is

avoiding mistakes due to unconscious actions.
Fundamentals training pursues the following aims:
▪ Conscious and improved recognition of hazards,
problems and disruptions
▪ Correct use of optical signals
▪ Safe walking and climbing
▪ Controlling Movements Safely
▪ Avoiding Dangerous Reflexes
▪ Correct working behaviour and avoiding
routine errors

This training is only the beginning. The skills acquired

here have to be practised. This is why we have
designed our sustainability training.
The aim is to connect the correct ”unconscious
behaviours” acquired during the training
session with real-life work situation and to
practice these behaviours.

▪ The sustainability training should last only

about 5 - 10 minutes.

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 31

 My topics for the Sustainability Trainings:

Topics

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

32
Preparation
During the Fundamentals training module of
”Safe Working Behaviour” you chose six tasks for
which you will carry out sustainability training with
your employees.
Each of these tasks should not take more than
5 minutes.

Execution
Select a task.
Discuss this task with 4 or 5 of your employees.
▪ Step 1:
Subdivide the task into a maximum of 4 steps.
▪ Step 2:
Consider with your employees, which of the
safe behaviours are required for each step.
▪ Perception (of hazards)
▪ Safe walking (fixation)
▪ Controlling Movements Safely
▪ Dangerous reflexes (avoiding)
▪ Working behaviour (correct process)
▪ Step 3:
Specify the right behaviour for each step:
▪ Check the area for hazards (60 seconds)
▪ Look at floor/steps while walking
▪ Controlling movements using your eyes
▪ Consciously consider: What makes me reach
into the dangerous area?
▪ Do I still have the correct chain of reactions?
© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 33
 Unconscious
Steps How do I behave correctly
behaviour

1.

2.

3.

4.

5.

34
Content

Introduction 3
Perception: Seeing and recognising hazards 4
Action Plan: Perception: Seeing and recognising hazards 6
Sustainability Check: Perception 7
Using optical signals correctly 8
Action Plan: Using optical signals correctly 10
Sustainability Check: Optical signals 11
Safe walking 12
Action Plan: Safe walking 14
Sustainability Check: Safe walking 15
Hand-eye coordination: Controlling movements safely 16
Action Plan: Hand-eye coordination:
Controlling movements safely 18
Sustainability Check: Controlling movements safely 19
Avoiding dangerous reflexes 20
Action Plan: Avoiding dangerous reflexes 22
Sustainability Check: Avoiding dangerous reflexes 23
Safe working behaviour 24
Action Plan: Safe working behaviour 28
Sustainability Check: Safe working behaviour 29
Methods for avoiding accidents 30
Sustainability Training 31

Contact for results of measures:

Name Job role Phone

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany 35

 Safety is always
the top priority!

INSTITUTE BRUNO SCHMAELING CONSULTING GROUP

SCIENTIFIC DIRECTOR PROF. DR. CHRISTIAN CALLO
Dorfener Weg 14, D 83104 Tuntenhausen-Hohenthann, Germany
Tel. 0049 (0) 8065 1092, Fax. 0049 (0) 8065 1093
consulting@ibs-schmaeling.com, www.ibs-schmaeling.com

© 2000/2022 Institute Bruno Schmaeling Consulting Group, Germany