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Behavioural Based Safety

 Profile

• 1998 Sep. Plant1 Mass production

Foundation
• 2007 Oct. Plant2 Mass production

• Land: Total 2,148,760m²(534 acres)

Area Plant 1: 178,512 m²
Plant 2: 191,735 m²

• USD $ 2.7 billion

Investment
• Vendor $ 1.2 billion

• Capacity 0.68 million units

Capacity per year (3 shift basis)
Plant 1: 0.34 million
Plant 2: 0.34 million

Manpower • Total 8463

Sales • 15 Regional Headquarters

• 394 Dealer shops
Network • 1000 Service points
 Plant Layout [Total 10 Models]

PDI
Foundry 2
Plant 2 Warehouse
Press 2
Engine 3

Plant 1 Body 2
Eng 2

Paint 2 CKD
Foundry 1
Eng 1 Assembly 2

Assembly1
Press1
Paint 1

Body1

Grand New
Eon Elite i20 Elantra Sonata SantaFe Creta Elantra Tyscon i10 Xcent Verna
Facelift New Model i10

Plant 1 Plant 2
 Process Flow

T/M

AL FOUNDRY

ENGINE SHOP
ASSEMBLY SHOP

PRESS SHOP BODY SHOP PAINT SHOP

COMPLETE CAR
 Automation Rate In HMI

Group Shop Line Automation Rate No Of Robots

A11  7.3% 4

Assy A12  6.3% 1

A13  2.4% -
P/Car #1
Paint P11 61.3% 48

Spot Welding - 100%

B11 Loading – 10%  180
Body Co2 Welding -100%

B12 Spot Welding - 50 % 7

Assy A21  7.8% 4

P/Car #2 Paint P21 61.3% 56

Spot Welding -100%
Body B21 Loading - 3.9 %  191

ETM 1 - 55 %

P. Train ETM 2 - 98 % 44

Eng 3 - 98 %

Total 62 % 535
 Human Behaviour is :
ABC Model

Observable Measurable
Therefore
Behaviour can be managed !

Attitudes

not observable or measurable

however
•Attitudes can be changed
by changing Behaviours
 ABC Analysis – Overseas Incident

A  Bus bar duct welding work not completed on

Sunday (12.02.17) during Power Shutdown
Activators

Bus Bar duct

3 persons engaged in Truss

welding work
 ABC Analysis – Overseas Incident

B  Pending welding work done on LIVE Bus bar duct on

Tuesday (14.02.17)
Behaviour

Intention
Live Bus Bar duct

Work completion without

line stop

3 persons engaged in Truss

welding work
 ABC Analysis – Overseas Incident

C Work Completion
Electrical Flash
without any incident
Consequences

Live Bus Bar

duct

Truss
3 persons
engaged in
welding work

 No production loss
 No Incident  Injury
 Appreciation  Production loss
 Corrective action
Reinforce the  Training
Unsafe behaviour
Weaken the Unsafe behaviour
 Leadership

Engagement

Training

Communication
Six Pillars of Behavioural Based Safety

Behaviour Based Safety

Recognition

Measurement
1st Pillar of Behavioural Based Safety

Leadership Behaviour Based Safety

Vision & Core values
Core Values
Top Management Commitment

Shop floor audit Shop floor visit Sr. Dir Admin, Mock Drill

Team Leaders Participating in

Fire Service Day National Safety Day Walkathon

Safety Training - Shutdown Safety Review Meeting – S/D

 Safety Ambassador – 2016 Journey
Inauguration & Training Culture Promotion By SA

77 Ambassadors
Dec
2016
Safety Communication Walkathon

Role Model Campaign

QTR QTR
1 2

QTR QTR
4 3
Cross Functional Review
Sure Q 4 Safety
& Motivation

Achievement Improvements
Identified - 1219
JAN
- 1087
2016
- 132
SAFETY AMBASSADOR – 2017 – ACTION PLAN

• Project Execution • Sustainable action

• Ambassador Nomination • REBA • Horizontal Deployment • Rewards &
• Across All Division • OCRA • Competition Appreciation
(Procurement, GA) • Midterm Review of • Evaluation
• Training for Existing & activities & Rewards
New Ambassador • Health Promotion
• Project identification Q4

Q3
Q2

Q1

LAUNCH BY TOP IMPLEMENTATION EFFECTIVENESS & REWARD &

MANAGEMENT
& MIDTERM REVIEW EVALUATION RECOGNITION
(6TH March)
2nd Pillar of Behavioural Based Safety

Behaviour Based Safety

Engagement
Leadership
Safety Anthem
 Safety Committee Meeting
1. Shop Safety Committee Meeting – Every Month
- HMI has formed 16 shop safety committees
Shop Safety committee
Shop Teamorganization
Leader structure
Chair Person

Shop floor Safety committee member –

Shop floor Safety coordinator – Shop floor Safety coordinator – Shop floor Safety committee member –
A Representative from Maintenance, QC,
A Representative from Safety Team A Representative from Shop floor A Representative from Technician
PMT and Engg.Team

2. UUHE Safety Committee Meeting – Every Month

UUHE Safety committee organization structure
Safety Team Leader
Chair Person
UUHE Safety Committee
Shop Safety Coordinators Safety Team
Members – 9 Persons
 Safety Committee Meeting
3. Central Safety Committee Meeting - Quarterly
Chairman
Sr. VP Production

Co-Chairman
Sr. VP HR&GS
Secretary
TL- F & S

Management Representatives Special Invitees Workers Representatives

 Group Head
P/Car 1
P/Car 2
P/Train
PPC
QC Team Leaders from Concerned Shop / UUHE Safety Committee Members
 Chief Medical Officer Maintenance on need basis [09 Members]
Representatives from:-
 Purchase Team
 Construction & Maintenance Team
 Employees Relations Team
 Contractor Safety Committee Meeting
 To communicate HMI safety requirements to Contractors
Objective  To identify deviations and prevent recurrence
 To ensure 100% adherence to safety regulations

 Contract : Job & Manpower  Safety

Target Participants Frequency Monthly Team
 Contractor Managers & Supervisors  Human Resources

Photos
Safety Suggestions/Near Miss Identification

Line Side Employees

observes Near miss /
Hazard / unsafe Act / Safety
Improvement .
Safety team evaluates the
performance of each line in
Fills the Safety Suggestion
co ordination with CFT
form
members & rewards the best
line.

Team leader organizes a

Monthly meeting in presence
Shop Safety discuss with
of Safety Circle members &
employee
updates the status of their
suggestion.

Shop Safety coordinator Shop Safety Coordinator

fixes a responsible person & analyses the suggestions &
follows it up. makes a report.
 Glimpse - Safety Competitions [Employees]

1. Safety Poster Making 2. Safety Photography 3. Safety Song

Total Teams
Contestants Contestants
22
91 130 Contestants

60

4. MITE [Morale Improvement through 5. Safety Short Film 6. Safety Model

Ergonomics]

Total Teams Total Teams Total Teams

24 14 11

Contestants Contestants Contestants

77 70 55

w
7. Electrical Safety Improvement
Ne 8. Bridge Competitions Total Participants
Total Teams
1 Safety Quiz 252
49
2 Cross Word 535 2056 Employees
Contestants
3 Spot the Hazard 228
105
4 Scrambled Word 405
Annexure II 20/54
 Glimpse - Safety Competitions [Contractors]
1. Safety Poster Making 2. Safety Debate

Contestants Contestants

59 186

3. Safety Quiz 4. Safety Slogan

Contestants Contestants
80 33

Safety Competitions – Employee Spouse & Children

Drawing Competition for Children Theme : Home Safety

Contestants
48

Special Training for Employees’ Spouses Topic : Domestic Safety

Annexure II 21/54
MITE [Morale Improvement Through Ergonomics]

Morale
【 Pallet Handling 】 【 Auto - Turn Table Rotation 】 【 Compressor Tightening 】
Improvement
Through
Ergonomics

【 First Prize 】 【 Second Prize 】 【 Third Prize 】

Annexure II 22/54
National Safety Day

Safety Model Displays Safety Anthem Release Bouquets to Chief Guest

Safety Day
Celebration

Safety Pledge Chief Guest Address

Top Management Address

Prize Distribution

Annexure II 23/54
Fire Service Day Competition 2016

Objective To enhance firefighting skills of employees and contractors

 To reduce panic in case of fire emergency

Date 10.06.16 Benefit
 To contain fire at the incipient stage

S No Category Time [Hrs] Team Participants Competitions

TOTAL 86 381 -

[4] Competitions : Target Shooting, Bucket

215
1 Employee – Men 08.30 ~ 12.00 43 Brigade, Fire Extinguisher Operation [T/U Booth
[5 Persons / Team]
Fire], Fire Hydrant Operation
Participant [3] Competitions : Fire Extinguisher Operation
Details Employee – 11
2 14.00 ~ 15.30 6 [Home Fire]
Women [2 Persons / Team]
Bucket Brigade, Fire Hose Reel Operation

Contractors - 110 [3] Competitions : Target Shooting

3 15.30 ~ 17.00 22
Men [5 Persons / Team] Bucket Brigade, Fire Extinguisher Operation

Contractors - 45 [2] Competitions : Fire Extinguisher Operation

4 14.00 ~ 15.30 15
Women [3 Persons / Team] [ Home Fire], Bucket Brigade

Inauguration

Annexure II 25/54
Fire Service Day Competition 2016

Employee –
Men

Target shooting Bucket Brigade Extinguisher Operation Hydrant Operation

Employee –
Women

Extinguisher Operation Bucket Brigade Hydrant Operation

Contract -
Women

Extinguisher Operation Bucket Brigade

Contract -
Men

Target shooting Bucket Brigade Extinguisher Operation Annexure II 26/54

Fire Service Day Competition

Hyundai Fire Service Day Celebration

3rd Pillar of Behavioural Based Safety

Behaviour Based Safety

Engagement
Leadership

Training
 Awareness & Education - Safety
Purpose To create and improve awareness on HMI safety policy and management systems
• All New Employees • Time of joining
Coverage • Project Trainees , Apprentice Trainee , Frequency • Re –Training ( Once in six
Diploma Trainees , Project months )

 HMI Safety Policy

 HMI Safety Management systems  Welding Safety
Training On –Job
 Work Permit system  Press Equipment Safety
Topics Training
 Fire Safety  Robot Safety
 Practical fire fighting training

Photos

New Employee Orientation Training Safety Training for managers

Result Improved Safety Awareness

 Education & Awareness - Fire Fighting 2

Purpose To create and improve awareness on fire safety & Fire fighting systems

• All New Employees , Project Trainees ,

Coverage Apprentice Trainee , Diploma Trainees , Frequency • Once in a week

 Fire Extinguisher  C02 Flooding system

On –Job
Training Topics  Fire Hydrant Operation  Deluge system
 Fire Fighting System
Training  Sprinkler system

Photos

Basic fire fighting Fire Extinguisher Fire Hydrant

Result Improved fire Safety Awareness

Health & Safety

 Awareness & Education – Fire Safety
Purpose To create and improve awareness on fire safety & Fire fighting systems

• All New Employees , Project Trainees ,

Coverage Apprentice Trainee , Diploma Trainees , Frequency • Once in a week

 Fire Extinguisher  C02 Flooding system

On –Job
Training Topics  Fire Hydrant Operation  Deluge system
 Fire Fighting System
Training  Sprinkler system

Photos

Basic fire fighting Fire Extinguisher Fire Hydrant

Result Improved fire Safety Awareness

 Vendor Engagement - Special Training for Vendors

Purpose Special Education to vendors on best practices

 Top Management representatives from

-J/V Vendors
Participants -I/V Vendors
 Fire In charges
 Procurement division employees

• Case Study – Georgia vendor plant fire incident

• Safety management
Content • Disaster Management
• Fire safety
- Fire due to overload, short circuit, leakage

Photos
 SAFETY AWARENESS TRAINING PROGRAMME for Vendors & Contractors 7
  Fire Fighting Training – Employee Family Members

Title Domestic Safety

Place Subhatra nagar, Sriperumbudur Participants 25 members

Facilitator Fire Officer, HMI

1. Kitchen Safety, Electrical safety

2. Basic of Fire & Types of Fire
Topics Covered
3. Types of fire extinguisher & methods extinguishing
4. Practical session on usage of Fire Extinguisher

Photos

Precautions to be taken while handling electricity & in kitchen

Result
Increases confidence level in handling fire

Health & Safety

 Helping Hand to society - Local community development

FIRE SAFETY TRAINING TO SCHOOL CHILDRENS

Neighboring Industries Support

FIRE SAFETY & LPG SAFETY TRAINING TO HOUSE WIFE
Health & Safety
4th Pillar of Behavioural Based Safety

Behaviour Based Safety

Communicatio
Engagement
Leadership

Training

n
 Communication Channel

Communication -Bottom Up
 Direct channel of communication
 Email option – myvoice@hmil.net
 The grievance are addressed and responded to the
employee within 10 working days

 A monthly communication meeting for Dy Managers & above participate.

 Every month departments share information about company performance,
new policies, matters of concern etc
5th Pillar of Behavioural Based Safety

Behaviour Based Safety

Communicatio
Engagement

Recognition
Leadership

Training

n
 Best Safety Team

Purpose To recognize and award “BEST TEAM” in SAFETY PERFORMANCE

1. Safety Committee meetings – Points compliance status.

2. Safety Audit - Compliance status
3. Recordable incidents - No of Incidents per 100 employees.
4. Man-days Lost due to Injury - Total Man-days lost per 100 employees.
Selection
5. Reportable Incident Rate – No of Incidents per 100 employees.
Criteria
6. Innovation Index – Safety innovation per 100 employees
7. OHSAS Audit - Internal & External Audit Observations
8. Channel Hyundai - Pick of the Month & Violations
9. Competitions - Participation & Prize winner

Photo Assembly Shop II

 Best Shift In-charge

Purpose To measure Safety Performance of Shift In Charges of a Group and motivate better performance

Safety score maximum :- 100 Marks

-: Leading Indicators :- -: Lagging Indicators :-

Indicators
1. Training (Max : 30) 1. Incident - (Max : 10 )
2. PPE Adherence (Max: 40) 2. Violations - ( Max: 10 )
3. Improvements / Near miss (Max: 30)

 Improves safety - Healthy competition among In charges

Result Frequency Monthly
 Award will be distributed in Group Head Review Meeting

Promotion
 Leadership

Engagement

Training

Communicatio
6th Pillar of Behavioural Based Safety

n
Behaviour Based Safety

Recognition

Measurement
 AWARD & RECOGNITION
Highest Reduction in Frequency
Rate 2
2 0
1st Lowest Weighted Frequency State Level – Safety
0 1 Appreciation Award
Prize 1 Rate
Longest Accident Free Period in 2
0
Man-hours

Excellence Award Excellence in Safety

2
Certificate of Commendation 02
10
Certificate2of Merit – Best Practices in EHS 2
0 31
0
1 2 41 Excellence in Safety
1 0 5
Certificate
1 of Commendation
2 2
0
1 Certificate of Merit
23
0
1
“3 STAR”
4 AWARD - EHS
HMG Group
- Best Safety Improvement Award 2012
(Overseas plants – 12, Domestic Plants – 03)

“3 STAR” AWARD - EHS

- 1st Quarter Safety KPI Evaluation 2016
(Overseas plants – 07, Domestic Plants – 10)
Summary

 Cultural Change that will take time

 Never ending process

 Must be employee driven

“Be the better Guy”

Total Safety

@ Work place

Road & other

Transport

Home

Public & other

places Outside Workplace 90%
Adventure &
Sports

Natural
Disaster
Preparedness

Practice Total Safety

♦ Your Family
♦ Your Friends
♦ Your Company
All need YOU
*Thank You