Learnings derived from incidents

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					Learnings derived from incidents
                                                                                                                                                                                                          1
                                                                                                                                                                                                          Safety
                                                                                                                                                                                                                   No.


                                                                                                                                                                                                          SAFETY CONCERNS ALL WORKERS




We are at the end of the first quarter of 2008 – a                                   Risk Standards is under way. In addition, the Risk                               We are constantly challenging ourselves in our
busy and exciting time! This issue of number 1                                      Assessment Review project will boost our drive                                quest for greatness and we, therefore, welcome any
reflects on selected safety and sustainable deve-                                    towards zero harm.                                                            comments and feedback.
lopment activities that received special attention                                     The electricity crisis in South Africa has been
during the past three months.                                                       an area of focus but once again has proven that we                            Yours in safety,
   Unfortunately, seven of our employees (five in                                    can reach new milestones if we put our minds to it!                           Deirdré Lingenfelder – group SHE manager
managed operations) were injured to the extent that                                    We are focusing on improved health manage-
they were not fit for duty. We will look at the inci-                                ment and as such a great deal of focus has been                               P.S. Remember to commemorate World Health and
dents, what happened and the learnings derived.                                     placed on the management of hygiene factors,                                  Safety Day on 9 May. Send your photographs.
   We have embarked on a number of                                                  medical surveillance and revitalising our voluntary
                                                                                                                                                                  Please forward any interesting SHE articles or
exciting projects. The roll-out of the Anglo Fatal                                  counselling and testing for HIV/AIDS.                                         photographs to sheadmin@scaw.co.za

                                                                                                                                                                                            Safety
                                                                                                                                                                                            Health
     a member of the Ferrous Metals and Industries Division of Anglo American plc    In the interests of the environment, where possible, please avoid printing this electronic newsletter. Environment
                                                                Employees who received Safety Fundamentals Training
                                                                at AltaSteel recently.




N*E*W*S*F*L*A*S*H Reviewing our risks, entrenching safety
Reviewing our risks                                                                                      Training in Canada

The Safety Risk Management Process (SRMP) is an Anglo-wide project and                                   Safety Fundamentals Training and an Internal Peer Review were
provides the knowledge to develop higher levels of capability in managing safety                         undertaken in Canada in February 2008. The training was well
risks. This is aimed at significantly improving our safety performance.                                   received by the AltaSteel and Maple Leaf Metals operations.



Head of the Safety Risk Programme, John              This training is referred to as “A3” training.     Safety Fundamentals Training has been revamped and includes the Anglo Fatal
Landmark, commented, “The programme is               The supervisors (A2) and employees (A1)            Risk Standards. The AFRS is a subset of Standard 2 which relates to risk and
tailored to be relevant to all levels of employ-     training will be rolled out in time.               change management.
ees. Each employee will go through the most
appropriate of four levels of the programme,         In addition, Scaw is undertaking a fresh look at
with content based on courses already delivered      its operational baseline risk assessments and      Anglo updates its SHE policy
at the University of Queensland in Australia.”       associated controls – an exciting and              Anglo American plc has updated its Safety, Health and
                                                     challenging project – as learnings will be         Environment policy, which is applicable to all
The Scaw Metals Group was on board from              shared across Anglo. This very important           operations in the Anglo group, including Scaw Metals.
the start of this project. Four line managers        project will commence at the Union Junction        Please turn to page three for the revised policy.
attended the initial training in Queensland.         main melt shop from where it will be extended
Subsequently, many top and senior managers,          across the group.                                       SHE initiatives
including the executive chairman, received
training. This level of training is referred to as
                                                                                                             Do you have any good SHE initiatives
                                                     Representatives from Anglo Ferrous and
“A4” training.                                       Industries, Scaw, the Camborne School of                that will benefit the group?
                                                     Mines and Dekra are involved in this exciting           Please forward them to
Additional managers will be trained in April.        project.                                                the group SHE department.
                          We hold leaders accountable for the safety of our people.                                              Line management is responsible and will be held accountable for the implementation of this     We hold our leaders accountable for the environmental management of our activities.
                                                                                                                                 policy and we expect all employees and contractors to contribute to maintaining a working
                                                                                                                                                                                                                                We expect our line managers and supervisors to provide effective leadership in environmental
                          We expect our managers and supervisors to provide effective leadership in safety whilst                environment that is without significant risk to health.
                                                                                                                                                                                                                                management whilst recognising that environmental management is the responsibility of all who
                          recognising that good safety behaviour is the responsibility of all those who work for us.
                                                                                                                                                                                                                                work for us.
                                                                                                                                 We commit to the reduction of exposure at source through good engineering practice and
                          Management of every business or operation is responsible for the full implementation of our            application of the ALARP1 principle; compliance with the law will always be the minimum        Managers of every business or operation are responsible for the full implementation of the Anglo
                          safety management system (the Anglo Safety Way), the Fatal Risk Standards and the Golden               standard.                                                                                      Environmental Management Framework and participation in the Anglo Peer Review Programme.
                          Rules. This requires the allocation of appropriate resources and the provision of training,
                                                                                                                                                                                                                                This requires:
                          education, consultation and auditing to ensure compliance.                                             We will provide appropriate resources, systems and training to protect, maintain and promote
                                                                                                                                 the health and working capacity of our people.                                                   the allocation of appropriate resources and the provision of training, education, consultation
                          We commit to open communication with our employees, contractors, suppliers and other business                                                                                                           and auditing to ensure compliance;
                          partners and interested third parties to encourage a safety culture that reflects the intent of this   We commit to open and transparent communication on occupational health with all
                                                                                                                                                                                                                                  the development, implementation and maintenance of environmental policies, programmes
                          policy.                                                                                                stakeholders.
                                                                                                                                                                                                                                  and procedures;
                          We will set appropriate objectives and monitor progress against these to ensure continual              We will set appropriate objectives and monitor progress against these to ensure continual        effective environmental impact identification, assessment and control, designed to achieve
                          improvement towards our goal.                                                                          improvement towards our goal.                                                                    proactive management of our activities, products and services.
                                                                                                                                                                                                                                We shall conserve and protect environmental resources through, amongst others, the efficient
CEO, Anglo American plc                                                                                                                                                                                                         use of energy and water, minimising waste and reducing pollution.
                                                                                                                                                                                                                                We shall demonstrate active stewardship of land, freshwater systems and biodiversity with
                                                                                                                                                                                                                                which we interact.
                                                                                                                                                                                                                                We respect people’s culture and heritage
                                                                                                                                                                                                                                We shall comply with environmental legislation and other requirements to which we subscribe,
                                                                                                                                                                                                                                and develop a culture of improvement.
                                                                                                                                                                                                                                We commit to open communication with our employees, local communities, contractors,
                                                                                                                                                                                                                                suppliers, investors, business partners and other interested parties to encourage an
                                                                                                                                                                                                                                environmentally responsible culture that reflects intent of this policy.
                                                                                                                                 1
                                                                                                                                     As Low As Reasonably Practicable
Achievements: Proacer scoring safety highs
Casting, Electrical Maintenance and Mechanical Maintenance
In November and December 2007, workers in the Casting & Electrical and Mechanical Maintenance departments (shown above) achieved one year without
any lost time injuries. This achievement is highlighted in consideration that these are high-risk areas, where personnel have evolved in their understanding
of safety fundamentals and have accepted that safety depends on their own behaviour. Congratulations to each team member.



In January 2008, Proacer in Chile, South          conditions at Proacer where the risk of injury is
America, was visited by two important organi-     high due to the handling of liquid steel. Proacer
sations in the field of safety and occupational    was congratulated for its good safety perform-
health in Chile.                                  ance in 2007.

The first group (right, top) consisted of 15       The second group (right) consisted of top-level
occupational health and environment students      national and international executives from the
from Contramet (the Metallurgical Association’s   company 3M, a supplier of personal protective
Union) and Seremi (the Ministry of Health).       equipment (PPE) to Proacer. They assessed the
These students are all union leaders in           manufacturing processes at Proacer and offered
various companies in Santiago. The main           suggestions on the improved use of PPE
purpose of the visit was to assess the working    material and cost reductions in PPE.
safety
 Performance
               Year-to-date the Scaw Metals Group has had
               seven injuries (five from managed operations)
               that have resulted in employees being unfit to
               perform their normal tasks. These incidents
               are described between pages 7 and 9.




               It is imperative that we learn from
               these incidents to prevent repeats.
safety
 Indicators and performance
 Hierarchy of controls

 All High Potential Incidents are investigated to make sure that we ascertain the root causes of incidents and to put the
 necessary corrective and preventative measures in place.



 As mentioned in our weekly newsletters and the last edition of number 1, identifying all the hazards in the workplace and determining
 the associated risks form the foundation of safety
 management. If the risk assessment indicates that                     ELIMINATION
 the hazard is significant, we must put the management                SUBSTITUTION
 measures in place and we must focus on the hierarchy
                                                                      ENGINEERING
 of controls:
                                                                    ADMINISTRATIVE
 Let us learn from these incidents.                                           PPE
 Discuss it with fellow employees and assist in
 making Scaw the safest steel producing plant in
 the world.
safety
 Indicators and performance
 LEADING INDICATORS

 We are increasingly focusing on leading indicators (these are warning signs that we need to pick up on before someone is injured). Some important leading
 indicators are:
 • Reporting near hits and minor injuries (these are distributed as High Potential Incident (HPI / MPI) reports daily) and sharing the learning to prevent repeats. We
     can also see trends from these leading indicators.
 • Being visibly felt leaders in the workplace, by conducting walk-abouts and engaging constructively with employees with regards to SHE matters. This is an
     important way of ascertaining whether we have issues to address. This is measured in terms of unsafe actions in the workplace (as a percentage of total
     observations).
 • Conducting Planned Job Observations. This tells us whether employees are doing their jobs safely.

 NEAR HITS

 According to the near hits recorded, lifting activities are by far the biggest cause of near hits. We should take the learnings from the near hit reports distributed via the Group SHE
 department and ensure that we implement corrective and preventative actions as specified.

 LAGGING INDICATORS

 10 January 08 – Union Junction: DRI Plant

 The injured was cooling lanced blasting holes in the kiln dam wall when an eruption of hot water and slag occurred. Cooling was done with water using a 2.7 m long steel lance to
 allow distance from the holes. The injured was standing 2 m away and to the side of the hole when the incident happened. He fell backwards approximately 0.5 m and injured his
 right arm, left eye and thigh, and sustained lacerations to the face. He subsequently lost his eye. He was wearing full PPE at the time, including safety glasses and a face shield.
 LEARNING: The hierarchy of controls was implemented and the activity of lancing the kiln dam wall has been engineered out. Water cooling walls will be used hence forth in the
 dam wall instead of refractories. In addition, instead of using face shields and safety glasses, safety goggles with elastic bands will be used hence forth.
safety
 Indicators and performance
 LAGGING INDICATORS

 27 January 08 – Union Junction: High Chromium Ball Plant

 The injured person was in the process of identifying ball spillage points. He placed his hand through an opening in a guard and used his shifting spanner to remove grinding
 media balls from the inside of the conveyor. In the process his hand was caught by the moving conveyor and it pulled his arm into the conveyor. The injured had not isolated the
 conveyor prior to attempting to remove the balls. He sustained deep lacerations to his right upper arm and shoulder area and a right fractured upper arm.
 LEARNING: All openings in these specific guards have been closed, and the project is being extended throughout the plant. As part of this process a management of change risk
 assessment was done and the Safe Work Procedures altered accordingly. Guards were extended in areas identified as part of the risk assessment.

 31 January 08 – Benoni Works: Core Shop

 The operator experienced problems with sand supply. He investigated and identified an air leak. He used his hand to identify the location of the air leak. The slide moved and
 caught the inured person’s finger.
 LEARNING: The machine was isolated until the investigation was done. The risk assessment and Safe Work Procedure was reviewed and safety fault finding rules built in. A
 guard for the sand slide was put in place.

 24 February 08 – Union Junction: Fettling

 The injured person walked past a running, cooling fan and stretched his hand out as he passed the fan, pushed his fingers through the guard and the blades cut his left
 middle finger.
 LEARNING: Appropriate and additional guarding was retrofitted on the fans.
safety
 Indicators and performance
 LAGGING INDICATORS

 27 February 08 – CWI

 An employee’s finger got trapped between a wire warp and drawing block. The prescribed tooling was not used.
 LEARNING: The inter-locked system was improved

 8 March 2008 – Proacer

 An arc furnace operator sustained burn wounds to his hand after an oxygen pipe caught fire.
 LEARNING: Steel protection was introduced on the lance and minimum lance lengths have been specified.

 13 March 2008 – Union Junction: Rod and Bar Mill
 The injured person was on a ladder, slipped and fell backwards and sustained injuries to his neck. A fellow employee was holding the ladder steady. The employee was holding a
 tool in one hand.
 LEARNING: When climbing down a ladder, four point contact is one of the minimum requirements.
safety
 Anglo Fatal Risk Standards (AFRS)
 What is the AFRS?

 Let’s first look at where the AFRS fits into Scaw’s SHE management system. Scaw has 12 standards (The Anglo Safety Way
 – contact the SHE department if you need a copy of this document) that form the foundation of the group’s SHE
 management system, namely:


 • Standard 1: Policy, leadership and commitment
 • Standard 2: Risk and change management. The Golden Rules and
   the AFRS are sub-sets to this standard!
 • Standard 3: Legal and other requirements
 • Standard 4: Objectives, targets and performance management
 • Standard 5: Training, awareness and competence
 • Standard 6 : Communication, consultation and involvement
 • Standard 7: Documentation and control of documents
 • Standard 8: Operational control
 • Standard 9: Emergency preparedness and response
 • Standard 10: Contractor and business partner management
 • Standard 11: Incident reporting and investigation
 • Standard 12: Monitoring, audits and reviews
safety
 Anglo Fatal Risk Standards (continued)
                   The fatal risk
                   standards are:




 1. Light Vehicle Standard (related to Golden        Golden Rule 8 – Safety Devices).                 focus on equipment, people and procedures.
    Rule 5 – Operation of Vehicles).              6. Isolation Standard (related to Golden Rule 4     The implementation of these standards must be
 2. Surface Mobile Equipment Standard (related       - Energy and Machinery Isolation).               completed by October 2010 and will require com-
    to Golden Rule 5 – Operation of Vehicles).    7. Working at Height Standard (related to olden     mitment and buy-in from all employees.
 3. Hazardous Material Management (related to        Rule 3 – Working at Heights).
    Golden Rule 6 – Molten Metal and Hazardous    8. Lifting Operations Standard (related to Golden   If you have not yet received a full copy of the
    Substances).                                     Rule 7 – Lifting and Mechanical Handling).       AFRS or if you have any questions about this
 4. Molten Metals Management (related to                                                              please contact the Group SHE department:
    Golden Rule 6 – Molten Metal and              These standards are aligned with the Golden         sheadmin@scaw.co.za.
    Hazardous Substances).                        Rules but where the Golden Rules focus on
 5. Equipment Safeguarding Standard (Related to   individual behaviour, the Fatal Risk Standards
                                                                                                                King Manikivana (left) from Rand Scrap Iron was
                                                                                                                commended for his safety diligence by a third party
                                                                                                                recently. He complied with all the safety requirements:
                                                                                                                • Making use of his seat belt.
                                                                                                                • Putting on the vehicle lights.
                                                                                                                • Wearing the required PPE.


safety                                                                                                          • Reversing with assistance.
                                                                                                                • Chocking the wheels whilst removing and
                                                                                                                    replacing a skip.



 Driving tips
 Keep yourself and your family safe on the road

 Travelling is a key component of the AFRS.
 Please take note of the safe driving tips below.


 Be a courteous and patient driver                        Safeguard your child                               • Make sure that you have the age appropriate
 To avoid road-rage and/or a collision:                 • Always secure your child in its seat with a          seat and seat belt for your child.
 • Allow at least a two-second timing between             seat belt, even if you are going on a short        • Install and use your child
     your car and the car in front, and use your          trip.                                                safety seat and safety belt
     horn only when necessary.                          • Children who are 12 and younger should be            according to the
 • If you feel that another road user is driving          restrained properly in the back seat, the safest     manufacturer’s
     too close to your vehicle, signal and pull over      place in the vehicle.                                instructions and
     when it is safe to do so to allow that driver to   • Never place a rear-facing child seat in the          your vehicle
     pass.                                                front seat of the vehicle.                           owner’s manual.
 • Keep your hands on the wheel and refrain
     from becoming offensive to other drivers.
safety
 Thank you!
 To all of our committed employees

 Thank you to each one of you that has made the effort to apply the safety information that has been communicated to the
 group. Employees who are committed to safe operating procedures are the building blocks of Scaw’s safety success.
 This page features some of those who have made the difference.
health
 HIV/AIDS
 In order to fight the battle against HIV/AIDS we will need to become heroes.
 An HIV hero will:




 • Be tested at least annually and motivate three   An annual schedule for voluntary
   colleagues to be tested in the same week.        counselling and testing has been
   Remember: The results are confidential and       circulated to the larger South African                Take charge,
   your status will not be revealed.                operations. This is to provide                      become a
 • Speak to those three people and ask them to      managers with the opportunity to plan                    super hero!
   be heroes by getting three more people to be     properly
   tested.
                                                    Please ensure that you are re-tested on an annual
 We would like to hear from our heroes. Let us      basis. It sets the right example and gives you
 know how you motivated your friends/colleagues     peace of mind regarding your status.
 to be tested. You can contact the Group SHE        If you are negative make sure that you stay
 department on 011 842 9302.                        negative.
health
 Health management
 Let’s get back to the basics of sound health management.
 Occupational hygiene and medical surveillance go hand in hand when it comes to preventing workplace illnesses.




 What is occupational hygiene?                        What is medical surveillance?              • A record of previous employment and expo-
                                                                                                   sure to hazardous substances.
 Occupational hygiene is the identification,       • Medical surveillance is the performing of   • A baseline for the health of the employee
 measuring, evaluation and control of hazards in     medical examinations and appropriate          when entering a new workplace.
 the workplace. This includes:                       biological tests. This includes:
 • Investigation and identification of hazards     • Pre-employment screening.                   Communication and co-operation between
     in the workplace to determine the need for    • Periodic medical examinations and tests.    employees, the occupational hygienist and the
     monitoring.                                   • Medical treatment.                          occupational medical practitioner may prevent
 • Measuring of employee exposure to occupa-       • Record keeping.                             occupational diseases. Employees must partici-
     tional hazards.                                                                             pate and co-operate in the monitoring process
 • Controlling exposure to hazards.                Pre-employment medical screening is very      as well as with the implementation of control
                                                   important because it provides:                measures.

 EMPLOYEES MUST REPORT FOR MEDICAL SURVEILLANCE WHEN REQUIRED. IF YOU NEED MORE INFORMATION CONTACT YOUR SUPERVISOR, YOUR SHE
 REPRESENTATIVE OR THE SHE DEPARTMENT.
environment
 Conserving energy – a changed mindest is required




 With a rising demand for energy in South Africa,      shortage of power is a global phenomenon.
 it is important to note that the current generation   We urge you to assist in creating awareness and
 capacity is under pressure. While in the past we      inculcating a culture of energy (electricity)
 have enjoyed significant surpluses of generating      awareness.
 capability, we now rely on imports and the buy
 back of electricity to sustain and meet the elec-     Please share the tips on electricity conservation
 tricity needs of the country.                         that appear on the following page with your
                                                       colleagues, staff, family and friends. You will
 Although this situation is new to South Africa, a     need to print out the page to read it.
                                                                      Using too much electricity?
                                                                             Here’s how to save!
                      ELECTRICITY CONSUMPTION OF ELECTRICAL APPLIANCES
                     1 line = 100 watt. A frying pan therefore uses 1 500 watts (15 lines).
                    1 000 watt per hour = 1 kW.h = 1 unit of electricity.
                    HOME:
                  Hair drier (400-1000 W)                    lllll                                             600 watt
                 Hair curlers                                llll                                              400 watt
                Hi-Fi                                        l                                                 100 watt
              Infrared lamp                                  lll                                               300 watt
             Electric Blanket                                l                                                 100 watt
            Lights (average 10x75 W)                         llllllll                                          800 watt
           Radio                                             l                                                 100 watt
          Vacuum cleaner                                     llllll                                            600 watt
         Iron (600-2 000 W)                                  lllllllllllllll                                 1 500 watt
        Television (66cm colour)                             lll                                               300 watt
       (48cm colour)                                         l                                                  80 watt
      (66cm black and white)                                 l                                                  70 watt
     Floor polisher                                          llll                                              400 watt
      KITCHEN:
     Dishwasher                                              llllllllllllllllllllllllllll                    2 800 watt
    Stove (3 000-8 000 W) depending on use
    2 plates and oven together                               llllllllllllllllllllllllllllll                  3 000 watt
   Frying pan                                                lllllllllllllll                                 1 500 watt
   Frier (rotating)                                          llllllllllllll                                  1 400 watt
  Toaster                                                    lllllllllll                                     1 100 watt
  Coffee filter                                              lllll                                             600 watt
 Kettle (1 500-3 000 W)                                      llllllllllllllllllll                             2000 watt
 Coffee grinder                                              lll                                               300 watt
 Microwave oven                                              lllllllllllllll                                 1 500 watt
Juice extractor (large)                                      lll                                               300 watt
Juice extractor (small)                                      l                                                 100 watt
Food mixer                                                   ll                                                200 watt
Freezer                                                      llllll                                            600 watt
Waffle grill                                                 llllllll                                          800 watt
Warming tray (Salton)                                        lllllllll                                         900 watt
HEATERS:
Oil                                                          llllllllllllllllllll                             2 000 watt
Fan                                                          llllllllllllllllllll                             2 000 watt
Ceramic/Capil                                                lllllllllllllll                                  1 500 watt
Panel                                                        lllllllllll                                      1 100 watt
LAUNDRY:
Washing machine
  (1) Not heated                                             llllllll                                          800 watt
   (2) Automatic
      (a) Heated                                             llllllllllllllllllll                             2000 watt
      (b) Wash/dry motor                                     llllllll                                          800 watt
 Tumble drier                                                llllllllllllllllllllllllllllll                   3000 watt
  Geyser                                                     llllllllllllllllllllllllllllll                   3000 watt
   GARAGE / WORKSHOP:
   Battery charger                                           llllll                                            600 watt
    Drill                                                    lllll                                             500 watt
    Grinder                                                  lll                                               300 watt
     Soldering iron                                          lll                                               300 watt
      Welder (portable
       and single phase)                                     llllllllllllllllllllllllllllll                  3 000 watt


         On your appliance you will see the number of WATTS that the appliance uses. This number is usually stamped
          underneath or at the back of your appliance.
           An iron for example uses 1 500 WATTS.
            This is 1,5 KILOWATTS.
             (To change WATTS to KILOWATTS move the comma three spaces to the left, i.e. 1 500 = 1,5 kilowatts)
                You then multiply the number of KILOWATTS by the price of one unit of electricity, for example 40 cents.
                 (1,5 x 40 cents = 60 cents)
                   This is the cost of using an iron for 1 hour.
                      REMEMBER TO CHECK WHAT THE PRICE OF A KILOWATT HOUR (UNIT) IS IN YOUR AREA.

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