WOLVEKRANS COLLIERY RISK MANAGEMENT PROCESS OVERVIEW 06 APRIL 2017

Transcription

1 WOLVEKRANS COLLIERY RISK MANAGEMENT PROCESS OVERVIEW 06 APRIL 2017

2 CONTENTS South32 Care Strategy Andre Roux Focus on Leading Indicators Nathi Ndlovu Application of Care Strategy: ICAM Approach Wihan Marx SLIDE 2

3 SAFETY PERFORMANCE OVERVIEW TRIF & Recordable Injury (RI/million man Hrs) Severity Rate (Days off/million man Hrs) TRIF (RI/million man Hrs) Jul'16 Aug'16 Sep'16 Oct'16 Nov'16 Dec'16 Jan'17 Feb'17 Mar' FY 13 FY 14 FY 15 FY 16 FY17 TD 0 RI 12 MMA TRIF 3 MMA TRIF SR (12 MMA) RI TRIF Budget Recordable Injuries 6 Recordable injuries for FY17 o 5 Lost time cases : 1 leg injury, 3 hand/finger injuries, 1 arm injury o 1 Medical treatment case : hand injury TRIF Performance (FY13 vs FY17 TD) o TRIF : 47% reduction o Recordable injuries : 57% reduction Zero recordable injuries relating to fatal risks. SLIDE 3

4 WVK RISK MANAGEMENT PROCESS HIRA - Baseline Risk Register - Issue based risk assessments - Continuous risk assessments Control Measures - COP s - SOP s & Standards - Managerial instructions - Task lists Feedback & Continuous Improvement Training - Risk assessments - Procedures - On-the-job training - Toolbox talks Supervision - Appointments - Competence - Familiar with risks Over-inspection - HRW Verification - CTO / PTO - Inspections & audits SLIDE 4

5 SOUTH32 CARE STRATEGY SLIDE 5

6 WVK CARE DASHBOARD Metric Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 FY17 Target Baseline Risk Assessments Planning & scheduling HSE Desktop Review Departmental engagement sessions and independent review by Risk & Governance Representative HOD Review & signoff On track Contractor Management Address gaps identified during the contractor management self assessment process. Participation and input in the Regional Contractor Management Standardisation Project. On track Zero Energy Reporting (Cumulative) # Compliance to Leadership VCL Schedule % Timeous Close out of Significant Events (<28 days) # Overexposure Occurrences (HEG s) # Medical Surveillance (Compliance) % Rehabilitation (Cumulative Hectares Seeded) # SLIDE 6

7 CONTENTS South32 Care Strategy Andre Roux Focus on Leading Indicators Nathi Ndlovu Application of Care Strategy: ICAM Approach Wihan Marx SLIDE 7

8 FOCUS ON LEADING INDICATORS Zero energy / hazard reporting Link to fatal risks and common themes Link to care strategy ( other category) Focus on H-level reporting (safety reps, artisans, operators). Over-inspections / verification Planned Task Observations Supervisors Critical Task Observations Superintendents & HOD s High risk work verification HOD s Timeous close out of actions action tracker Learnings from ICAM s DMR inspections and audits Internal audits Independent / peer reviews Continuous improvement SLIDE 8

9 HIGH RISK WORK VERIFICATION PROCESS HIGH RISK WORK MANAGEMENT No Responsible Task Description Area 1 Zweli Ntuli Load testing DEMAG Crane Diesel WS North Planned Date Associated Fatal Risk/s 23-Mar-17 Lifting operations Infrequent Task? HOD Verification Yes No Yes No Verifier 2 Pieter Coetzee Load testing WOLFF B Crane DTD 23-Mar-17 Lifting operations Identify high risk activities 3 Zweli Ntuli Change main Hydraulic pump 994/80 Diesel WS North 28-Mar-17 Lifting operations Ian 5 Maponti Phetla Change Position 3&4 Tyres TKDM331 Tyre Bay 29-Mar-17 Lifting operations 6 Danis Middleton 777/16 - Final Drive Change Out SKS 20 to 24-Mar-Uncontrolled release of 17 energy Sipho Report findings Rate activities 7 Danis Middleton 8 Danis Middleton 777/17 - Bucket Pins & Cylinder SKS 20 to 24-Mar-Uncontrolled release of 17 energy 777/16 - Brake Audit SKS 23-Mar-17 N/A 9 Wilson Phoko 785/35 - Brake Audit SKS 23-Mar-17 N/A 10 Wilson Phoko 785/28 - Brake Audit SKS 23-Mar-17 N/A 11 S.Zwane 789/66-Replace Diff and R/H final drive BMK 12 S.Zwane 789/60-Replace Engine BMK 13 Adries Botha 4W Mech Serv Crane/WinchDgln DRGM012 BMK 20 to 24-Mar-Uncontrolled release of 17 energy 20 to 24-Mar- 17 Lifting operations 23-Mar-17 Uncontrolled release of energy Alan Danie 14 J Labuschagne 5012 Replace bucket BMK 23-Mar-17 Lifting operations Conduct verification Prepare high risk work report 15 K Mcwagana 5012 Repair Tub liners BMK 23-Mar-17 Confined spaces Romeo 16 Willy Kgomo LDWM702 PVT BMK 23-Mar Willy Kgomo Comp change BMK Uncontrolled release of energy 20 to 24 Mar- N/A Matodzi 17 Identify activities to be verified 18 S.Zwane 994/85 crankshaft seal leaking BMK 19 Danis Middleton 20 Kobus Van Vuuren 777/16 - Final Drive SKS 22 to 24 Mar-Uncontrolled release of 17 energy 27 to 31-Mar-Uncontrolled release of 17 energy Theuns 5006 Replace LH & RH Boom Cylinders VDD 28-Mar-17 Fall from height Dereck 21 S.Zwane Crane W Service BMK 27-Mar-17 Lifting operations Mariska 22 S.Zwane 994/85 Replace crankshaft seal BMK 27-Mar-17 Lifting operations 23 S.Zwane 789/59 16W OEM Brake Audit BMK 29-Mar-17 Uncontrolled release of energy 24 S.Zwane 789/60 Remove and Replace engine BMK 27 to 31-Mar- Lifting operations Andre R Ratlhagana Modi mining working close to at-risk highwall (D1-D3) HBF 23 to 29 March-17 Opencast strata failure Nathi 26 F Smit Welding in dragline tub KFN 23 to 29 March-17 Confined spaces Sphiwe SLIDE 9

10 OUR OVER-INSPECTION APPROACH : PTO/CTO TRACKING Wolvekrans Colliery Leading Indicators - South (Production) 01 February 2017 CTO (Production & Maintenance) NAME & SURNAME DEVIATIONS TARGET MTD TARGET CTO PTO VARIANCE Danie Fourie Lerato khoza Jacques Pretorius John Mbatha Anton Homann/ Francious Grobler Themba Ngcobo Dawie Combrink Jacob Mofokeng/ Refiwe Legotlo Dirk du Plooy Johan Naude/ Musa Nxumamlo Simphiwe Mnguni Jabulani Mbokane Gilbert Phakoago Callie van der Merwe Skhumbuzo Madonsela Alwyn du Preez/ Constance Skosana CTO Tracker TOTAL NOT ON SYSTEM PTO - Jacques Pretorius NAME & SURNAME DEVIATIONS TARGET MTD TARGET CTO PTO VARIANCE Arone Dlamini Peter Magokong Vincent Phaahla John Nkambule Mishack Mbuli./ Bleeker Martinus Nombuso Morufane/ Andrew Ndaba TOTAL PTO - John Mbatha NAME & SURNAME DEVIATIONS TARGET MTD TARGET CTO PTO VARIANCE Sipho Mongomezulu Lerato Khoza/ Yvonne Mabena Prudance Ngwenya Andrew Magabe Willem Ludick Kgatla Mokgadi / Shirley Mantjie Precious Dladla TOTAL PTO - Anton Homann NAME & SURNAME DEVIATIONS TARGET MTD TARGET CTO PTO VARIANCE Petros Moetanalo Francois Grobler Dawied Fortuin Gerrit Le Roux/ Mpho Nkholise PTO Tracker Patrick Nkosi Tiny Nkosi Stephen Mokwena Sipho sibanyoni Pearl Mogano TOTAL NOT ON SYSTEM NOT ON SYSTEM NOT ON SYSTEM SLIDE 10

11 ACTION TRACKER SLIDE 11

12 CONTENTS South32 Care Strategy Andre Roux Focus on Leading Indicators Nathi Ndlovu Application of Care Strategy: ICAM Approach Wihan Marx SLIDE 12

13 APPLICATION OF CARE STRATEGY - ICAM APPROACH SLIDE 13

14 ICAM CHART KEY FAILURES Workplace The nature of the task (fitment of lock ring) creates a risk of uncontrolled stored energy. The weight of the lock ring is 48kgs and in the process of fitting the lock ring one of the fitters must let go of it, to start wedging it into position. The other fitter then needs to hold the lock ring in position until it is secure. Tools and Equipment No tool is available to cut/remove a stripped nut whilst the tyre is mounted,(no hot work near tyre allowed) this necessitates the vertical removal and fitment of a tyre even if it is only one nut that is stripped. There's currently no mechanism to lift and hold the lock ring in position. The use of a clamp that was investigated was not successful as this was deemed to create additional risks to employees. Design of lock ring creates a risk of pinch points Weight of lock ring is 48kg The lock ring material and design will cause it to have a spring reaction should it fall. Processes A works order was created for the task however no PRT was attached PRT does not include vertical fitment of tyres Hand signals used by the tyre bay team are not documented in the current procedure Works order can be created and released without attaching the relevant PRT No issue based risk assessment in place for tyre mounting, dismounting and inflating People Rimex training which is additional training for competent and authorised fitters expired in SLIDE 14

15 PREVENTIVE AND CORRECTIVE ACTIONS Action 1 Investigate options for safe handling and lifting of the current lock rings. 2 Investigate the possibility of replacing the current lock rings with split rings 3 Investigate the possibility of modifying the current lock rings into split rings 4 Investigate design of a specific clamp for holding the lock ring in position during fitment 5 Review SOP and associated CTO, PTO and PRT's to address the gap identified during the investigation.(eg. Hand signals) 6 Conduct an issue base risk assessment for tyre mounting, dismounting and inflation 7 Investigate the possibility to notify the individual before printing a works order without a PRT attached to it. 8 Investigate the practicality of using nut splitters to remove stripped nuts SLIDE 15

16 PREVENTIVE AND CORRECTIVE ACTIONS Tools & Equipment Lock Ring Clamp Stripped Nut Removal SLIDE 16

17 WOLVEKRANS ROLE MODEL OF THE WEEK SOUTH AND NORTH TYRE TEAMS LIVED THE VALUES AND THE WAY WE WORK BY: In line with our Care Strategy and values, the tyre teams at Wolvekrans Colliery had an exceptional response to a finger incident. In January 2017 a tyre fitter pinched his finger during the installation of a lock ring, which resulted in a LTI. Through inclusivity and by demonstrating the value of Togetherness our two tyre teams, Safety Technician and DTD machine Shop Fitter manged to successfully implement controls to prevent a reoccurrence of such an incident. They designed a clamp to hold the lock ring in place during the installation and removal of a lock ring. They also came up with a method to remove stripped wheel nuts without using flame cutting or grinding. The drilling of the nut can be done while the wheel is still in place which will minimise the vertical fitment of wheels. CONTACT DETAILS SOUTH SUPERVISOR On Friday 10 March 2017 the Department of Mineral Resources (DMR) came to investigate this incident and the teams were commended on the way they approached and implemented these mitigation actions. We would like to thank these teams for their dedication and teamwork, living out our Care Strategy. aubrey.komane@south32.net CONTACT DETAILS NORTH SUPERVISOR maponti.phetla@south32.net DEMONSTRATED CARE TOGETHERNESS SLIDE 17

18 PREVENTIVE AND CORRECTIVE ACTIONS Processes Issue based risk assessment review SOP Review & Training Supervision & Over-inspection SLIDE 18

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