INTEGRATED ANNUAL REPORT 2012

Think Future. Think Aluminium. Think Hulamin.

SAFETY

Philosophy and why it is important

Hulamin is committed to the wellbeing of employees and providing a safe working environment that ensures that the business continues to function effectively.

Hulamin has embedded a culture of safety in the organisation to ensure that its manufacturing plants are operated safely and employees are protected from injury or from harm due to incidents or exposure. To achieve this, employees and the teams in which they work are guided and supported in taking responsibility for their own safety. Hulamin seeks to continuously improve its safety performance by measuring and monitoring both leading and lagging indicators which are aligned with industry best practice.

Approach

The Hulamin Executive Committee is accountable for safety in the organisation. There are formal structures in place to identify, evaluate, and control operational risks. The Hulamin Safety, Health and Environment Committee meets quarterly to formulate policy, entrench standards, assess risks and ensure visibility at shop floor level.

Employees are expected to take ownership of their own safety, however, management provides structured direction aimed at inculcating a culture of safe behaviour. Line management is responsible for safety in their respective areas and is centrally supported by the Safety, Health and Environment team. Hulamin is audited for verification and compliance in line with the OHSAS 18001 Standard annually. All management structures are involved in the Visible Felt Leadership processes, which involve a walkabout on the shop floor to discuss progress and identify barriers and constraints to improving performance.

Hulamin is currently developing the “Hulamin Way” with respect to health and safety. This strategy approach will align the behaviour based safety (BBS) and the IMA Visual Management programmes. It will also focus on the development and implementation of critical standards to entrench a culture of compliance and benchmarking to international best practice. The ISO 14001 and OHSAS 18001 management system requirements will be incorporated into the strategy.

The concept of shop floor ownership is entrenched through visual management at mini-business unit level by monitoring and measuring the proactive and reactive indicators such as injuries, near misses and risk behaviours. This approach ensures both occupational and process safety systems are adhered to in order to ensure good safety performance.

These systems include:

Occupational safety systems
Process safety systems
2012 Performance

Hand injuries contribute to approximately 45% of all injuries and therefore remain a focus area of the safety programme. Hulamin has developed a hand protection standard based on the South African National Standards (SANS) 1340 part 4, which is aligned to European Standard EN 420:2003. Most of the hand injuries are related to cuts, therefore emphasis is being placed on the selection of the most suitable gloves relating to mechanical risks as per European Standard EN 388: 2003 requirements. A formal risk assessment approach has been adopted to identify which machine centres require approved cut resistant gloves based on the tasks, frequency of exposure and injury profile.

The following bar chart shows a significant reduction in total injuries over the last 12 years, but the percentage of hand injuries in relation to total injuries has remained relatively consistent.

SAFETY PERFORMANCE

Indicators Target Actual
Rate Number of incidents Rate Number of incidents
2012 LTIFR 0,20 7 0,33LA 9
2012 TRCFR 0,90 30 1,00LA 27

 

Comparative table

  Rate Number of incidents   Rate Number of incidents
2012 LTIFR 0,33LA 9 2012 TRCFR 1,00LA 27
2011 LTIFR 0,53LA 15 2011 TRCFR 1,31LA 37
2010 LTIFR 0,33LA 10 2010 TRCFR 1,81 55
2009 LTIFR 0,31 10 2009 TRCFR 1,16 37

 

Although total injuries are decreasing, lost time injuries remain high. This year the most common cause of serious injuries was related to operations that required two persons and communication between both parties. Communication channels have been improved and engineering modifications have been applied to reduce the risk through the use of interlocking devices such as pressure mats and limit gates.

Hulamin uses two measures to report safety performance. The Lost Time Injury Frequency Rate (LTIFR) and the Total Recordable Case Frequency rate (TRCFR).

There were nine lost time injuries (LTIs) in 2012. The incidents experienced encompassed the following:

There were noLA fatalities in 2012.

Hulamin has introduced the behaviour-based safety Visual Process Auditing (VPA) chart as a means to identify critical at risk behaviours. This has replaced the formal PACT observation and reinforcement system as the charts are updated daily and the “meaningful discussions” are part of the “eight minute” daily mini-business unit level one-process meetings. This ensures that the safety information is integrated into the IMA Visual Management process and is no longer operating independently. This has largely also created a paperless system for the BBS process.

The SABS conducted a surveillance audit on compliance with OHSAS 18001: 2007 and ISO 14001 Standards and the findings are being resolved through a formal action plan system.

LA Limited assurance provided by independent assurance provider.