301 Coal Miners died in an

occupational accident in
Soma in 2014.

Health and Safety Management System to Prevent Workplace Accidents

Melih Güneri

M.Guneri / HS Mang. 1
 Health and Safety Management System
Agenda
Phase 1 - Policy Phase 2 - Data Collection

• Setting Policy • Unsafe Act, Unsafe Condition

• Identying Target • Accidents and Near Misses
• Setting KPIs • Health Checks, Indoor
• Master Plan Environmental Conditions
• Creating a Team Measurements

Phase 3 - Risk Assessment Phase 4 - Audit & Revision

• Risk Assessment Flow • System Audits

• Controls, Preventive Actions • KPIs Evaluation
• Improvements • Revision on Master Plan
• Behaviour Change
Programmes / Indirect
Trainings

M.Guneri / HS Mang. 2
 Phase 1 – Policy

Setting Policy

Must be committed to all employees to prevent accidents and occupational illness

Different
industrial sectors
can add extra
Less Automated Industries commitments
• Provide best practise of
manual handling.

Chemical Industries
• Provide the best working
environmental condition possible

M.Guneri / HS Mang. 4
 Phase 1 – Policy
Identifying Target

• Key Performance Indicator (KPI)

• Key Activity Indicator (KAI)

Policy
Number of
Number of Number of Occupational Number of Percentage of Number of Number of Number of
KPIs Accidents Near Misses Illness Medical Absenteeism Unsafe Unsafe Acts Training
Syptoms Condition

Risk Analylsis                

Ergonomic                
Analysis
Medical                
Health Check
Unsafe Acts                
Observation
KAIs System
Unsafe                
Condition
Observation
System
Trainings                

Audits                

M.Guneri / HS Mang. 5
 Phase 1 – Policy
Setting KPIs

Team KPI
2014
Realization 2014 Target 2015 Target 2016 Target 2017 Target 2018 Target 2019 Target 2020 Target
Number of
Accidents
         
Number of Near
Misses
         
Number of
Occupational
Illness          
Number of
Medical
Syptoms          
Percentage of
Absenteeism
         
Number of
Unsafe
Condition          
Number of
Unsafe Acts
         
Number of
Training
         

M.Guneri / HS Mang. 6
 Phase 1 – Policy
Master Plan

Phase I Phase II
ROUTE STEPS
2014 2015 2016 2017 2018 2019 2020 2021
               
1 Assess Current Situation
               
2 Restore Basic Conditions
               

3 Accident & Near Miss Analysiss

               
4 Risk Analysis
               
5 Set up Data Collection System

Proactive Work Place                

6
Improvement

7 Innovative Improvements

8 Eradicate a specific risk

Set Up Advanced Emergency
9
Management System

M.Guneri / HS Mang. 7
 Phase 1 – Policy
Creating a Team
An Exapmle Of Team

• HS Resposible / Team leader

• Workplace Doctor / Team Member
• HS Support Employees / Team Member
• Production Responsible / Team Member
• Maintenance Responsible / Team Member
• Production Worker / Team Member

  Team
HS Workplace HS Support Production Maintenance Prod.
Tasks Resposible Doctor Employees Responsible Responsible Worker
Strategy & Targets Responsible     Assistant    
Method Responsible Assistant Assistant Assistant  
Master Plan Responsible     Assistant    

Trainings Assistant Assistant     Responsible  

Accident & Near miss Responsible Assistant Assistant Assistant Assistant Assistant
Occupational Illness & Assistant Responsible Assistant      
Medical Syptoms
Assistant
Unsafe Acts Assistant     Assistant Responsible  
Unsafe Conditations Assistant Assistant     Responsible Assistant

M.Guneri / HS Mang. 8
 Phase 2 – Data Collection

Unsafe Act, Unsafe Condition

Unsafe Conditions Rewarding
Unsafe Condition Reporting system is
the key !
• Employees reports
• Advantage :
unsafe conditions by Disadvantage:
visibly marking

Unsafe Acts
• Employees reports
unsafe conditions by
software application. Unsafe Acts Observation
• Advantage :
and Reporting
Disadvantage:
• Employees observe
themselves and
• Advantage report
Disadvantage: • Advantage
Disadvantage: • Selected group
observe and report

M.Guneri / HS Mang. 9
 Phase 2 – Data Collection

Accidents and Near Misses

Near miss Reporting

• Area responsible
reports

• Employee reports his

own near miss.

Accidents Reporting

• Area responsible
reports

M.Guneri / HS Mang. 10
 Phase 2 – Data Collection

Health Checks, Indoor Environmental Conditions Measurements

• Health check results

comparison present
and previous year.

• Datas for health Results

checks
• Noise
• Dust
• Vibration
• Lighting
• Chemical Vapours
• Thermal Comfort
• Ventilation
• Micro-organism on
equipments
M.Guneri / HS Mang. 11
 Phase 3 – Risk Assessment

Risk Assessment Flow

2.Evaluate The Risks

1. Collected
Datas

4.Evaulate the
effectiveness of
actions

3. Take Preventive
3.Train the
Actions, Controls,
employees
Improvements
M.Guneri / HS Mang. 12
 Phase 3 – Risk Assessment

Controls, Preventive Actions

Output of risk analysis for
Output of risk analysis for control Preventive Actions

What to control ?

• Electronic safety systems or

manuel safety sytems
To abolish to use unsafe knives
• Emergency control systems

• Electricity system

• Lifting eqipments, presure pots

• Other Equipment

Evaluation on Counter
Measure Ladder
M.Guneri / HS Mang. 13
 Phase 3 – Risk Assessment

Improvements

Before After

Do improvements and
display on boards !
M.Guneri / HS Mang. 14
 Phase 3 – Risk Assessment

Behaviour Change Programmes / Indirect Training

Objectives Activities
• To support the change of habits and
operational blindness • Safety Man
Characters

• HS slogan
contest

• Role Playing
Games

• HS Week
Celebrations

• ‘0’ Accident
Theme Social
Activities
Super Hero / Safety Man HS slogan contest among
Character employees
M.Guneri / HS Mang. 15
All designed by Lütfü Altan
 Phase 3 – Risk Assessment

Behaviour Change Programmes / Indirect Training

‘0’ Accident Theme Social Activities Role playing HS games

HS Week Celebrations M.Guneri / HS Mang. 16

 Phase 4 - Audit & Revision

System Audits
Internal Audit External Audit

What to audit ? What to audit ?

• KPIs • Total system

• Reporting system (Data

Collection)

• Controls and preventive

actions (Risk Assessment)
Outputs
• Programmes, campaings

• Follow up system
What can do better ?
Correct the failures and
Improve the system
M.Guneri / HS Mang. 17
 Phase 4 - Audit & Revision
KPIs Evaluation
Team KPI
2014 2014 Target 2015 Target
Realization

Number of Accidents 2 0
Why did
  we
Number of Near
Misses 10 5 perform
 
bad ?
Number of
Occupational Illness 0 0

Number of Medical
6 15
What we Identfy the
Syptoms
 
did good to causes and
achive the effects
Percentage of
Absenteeism % 0.5 2% target ?
 

Number of Unsafe
Condition 90 100

 
Number of Unsafe
Acts 150 50
  Did we set
Number of Training 18 30 right
  target ? M.Guneri / HS Mang. 18
 Phase 4 - Audit & Revision
Revision on Master Plan

Phase I Phase II
ROUTE STEPS
2014 2015 2016 2017 2018 2019 2020 2021
               
1 Assess Current Situation
               
2 Restore Basic Conditions
               

3 Accident & Near Miss Analysis

               
4 Risk Analysis
               
5 Set up Data Collection

Proactive Work Place                

6
Improvement

7 Innovative Improvements

8 Eradicate a specific risk

Emergency Management
9
Perfection

10 Behaviour Change Programmes

M.Guneri / HS Mang. 19
 Results

Automative Industry with appx. 700 employees

% 60 decrease in the number of accidents/Incidents
% 40 accident related property damage cost decrease
% 10 employee satisfaction increase
In 2 Years

Packaging Industry with appx. 300 employees

% 40 decrease in the number of accidents/Incidents
% 30 accident related property damage cost decrease
% 4 employee satisfaction increase
In 2 Years
M.Guneri / HS Mang. 20
Thank you

M.Guneri / HS Mang. 21