Learnings derived from incidents
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 firstname.lastname@example.org
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,
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
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.
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.
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.
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
Let us learn from these incidents. PPE
Discuss it with fellow employees and assist in
making Scaw the safest steel producing plant in
Indicators and performance
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
• 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
• Conducting Planned Job Observations. This tells us whether employees are doing their jobs safely.
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.
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.
Indicators and performance
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
LEARNING: Appropriate and additional guarding was retroﬁtted on the fans.
Indicators and performance
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.
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
Anglo Fatal Risk Standards (continued)
The fatal risk
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 email@example.com.
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.
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.
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.
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
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.
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.
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.
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
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
Oil llllllllllllllllllll 2 000 watt
Fan llllllllllllllllllll 2 000 watt
Ceramic/Capil lllllllllllllll 1 500 watt
Panel lllllllllll 1 100 watt
(1) Not heated llllllll 800 watt
(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
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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