Transformation to Total Workplace Safety and Health Lucas NG HK General Manager of Plant bizSAFE Convention 2017 14 February 2017, MAX Atria, Singapore Expo Convention & Exhibition Centre

Petrochemical Corporation of Singapore (Private) Limited

Transformation to Total Workplace Safety and Health

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1. Introduction 2. Management Ownership 3. Management must have Holistic Action Plans 4. Management to take Lead – Top-down and

Bottom-up 5. Workplace Safety and Health Programmes 6. bizSAFE initiatives 7. Conclusion

Source: butterfly - website

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Transformation to Total Workplace Safety and Health

1. Introduction 2. Management Ownership 3. Management must have Holistic Action Plans 4. Management to take Lead – Top-down and

Bottom-up 5. Workplace Safety and Health Programmes 6. bizSAFE initiatives 7. Conclusion

Source: butterfly - website

1. Introduction – PCS

4 Source: PCS

Upstream company of Singapore Petrochemical Complex on Jurong Island

1977 – incorporation

1984 – first ethylene plant (cracker) in Southeast Asia on stream

1997 – second cracker unit on stream

Present shareholders Japan-Singapore Petrochemicals Co., Ltd (50%) (JSPC led by Sumitomo Chemical) QPI and Shell Petrochemicals (Singapore) Pte Ltd (50%) [*QPI: Qatar Petroleum International]

supply high quality ethylene, propylene, acetylene, butadiene, 1-butene, MTBE and benzene to companies within Island

Incorporation of PCS – 10 August 1977

T Fukuda Japanese PM

T Hijikata President, SC Chairman, JSPC Vice-chairman, PCS

Lee Kuan Yew PM

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Reception on Incorporation of PCS – 14 August 1977

Hon Sui Sen FM

Source: PCS

PCS 1st Ethylene Plant Start-up – 18 February 1984

6 Source: PCS

First PM Mr Lee Kuan Yew visited PCS – 13 January 2001

Mr & Mrs Lee visited PCS Central Control Centre accompanied by

government officials

7 Source: PCS

Jurong Island Singapore

8 Source: websites

Jurong Island

1. Introduction – PCS

1. Introduction – Transformation

9 Source: PCS

Major transformation to

Total WSH Believe solutions

to problems Believe Zero

incident target achievable

Achieved: >12 years + >35

million worked hours LTI Free

PCS had painful falling from height incident in 2004 Management made

major transformation

Sharing on Safety and Health - content as reference modify to suit situation - welcome further engagement

2011 bizSAFE Mentor

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Transformation to Total Workplace Safety and Health

1. Introduction 2. Management Ownership 3. Management must have Holistic Action Plans 4. Management to take Lead – Top-down and

Bottom-up 5. Workplace Safety and Health Programmes 6. bizSAFE initiatives 7. Conclusion

Source: butterfly - website

2. Management Ownership

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Management ownership / responsibility not sole duties of safety and health personnel

Design for workplace safety and health plan for incident-free workplace

Never bet on luck – understand cause-and-effect never provide budget “waiting” to cover incident cost

Concerns many safety and health incidents occurred

Always feeling vulnerable; chronic unease

Management ownership / responsibility

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Responsible Care®

Committee

HSE Management Committee

Safety & Health Working

Committee HSE Promotion

Committee Contractors

HSE Committee

Function HSE Committees

HSE Function

Petrochemical Complex Contractors Association (PCCA)

(Regulatory Requirement)

Management Advisory

Board

Source: PCS

2. Management Ownership (cont’d)

5 HSE personnel but entrenched in all employees and in-house contractors

(Chaired by CEO)

(Chaired by GM of Plant)

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Transformation to Total Workplace Safety and Health

1. Introduction 2. Management Ownership 3. Management must have Holistic Action Plans 4. Management to take Lead – Top-down and

Bottom-up 5. Workplace Safety and Health Programmes 6. bizSAFE initiatives 7. Conclusion

Source: butterfly - website

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Risk Management

• Hierarchy of Risk Control • Elimination • Substitution • Engineering /

Isolation • Admin /

Training • Personal

Protective Equipment

Risk Assessment

• Formal Risk Assessment

• In-situ RA / KYT just before performing task

Permit-to-work System

• Permit-to-work authorisation form

• Workplace / condition verification

• Supervision

Safety Culture

• Individuals follow rules and regulations even if no one around

• Self control

3. Management must have Holistic Action Plans

Transformation to Total Workplace Safety and Health – I want Myself Safe

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Hierarchy of Risk Control

Best

Con

trol E

ffect

iven

ess

3. Management must have Holistic Action Plans (cont’d)

Planned Work

Workplace Preparation

Risk Assessment

(RA)

Permit-to-Work

Approved

In-situ Risk Assessment

(iRA)

Commence Work

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In-situ Risk Assessment

In-situ Risk Assessment derivative of KYT - kiken yochi training (Japanese 危険予知訓練)

Workplace conditions changing

Re-assess at site

Ensure safe to work

3. Management must have Holistic Action Plans (cont’d)

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Transformation to Total Workplace Safety and Health

1. Introduction 2. Management Ownership 3. Management must have Holistic Action Plans 4. Management to take Lead – Top-down and

Bottom-up 5. Workplace Safety and Health Programmes 6. bizSAFE initiatives 7. Conclusion

Source: butterfly - website

4. Management to take Lead – Top-down and Bottom-up

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Learn lessons from others • Capacity

building • Competency

development • Set achievable,

realistic target

Workplace Safety & Health programmes • Feedback

without penalty

• Suggestion scheme – work, productivity, safety

Rewarding system • Progression • Recognition • Continuous

improvement

A top-down and bottom-up approach two way communication

Two way Communication – Top-down

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• Be vigilant in all safety risks • Sense of vulnerability / chronic unease

– pointers for risk elimination • Cultivate and preserve safety culture

Proactive Leadership

• Be visible, accessible, walk at sites • “See for yourself”, walk the talk • Know status of facilities, support for

timely rectification of defects

Senior Management with

Line Managers

• Treat Contractors as partners • Work with Contractors Association • Include Contractor Representative in

Responsible Care Committee

Senior Management with

Contractor Management

4. Management to take Lead – Top-down and Bottom-up (cont’d)

Two way Communication – Bottom-up

20 Source: PCS

• Peer-to-peer Behaviour Based Safety Observation (BBSO TRUsT)

• Speak Out for Safety (SOS)

Blame-Free Environment

• Stop ongoing unsafe activities and report to superior

• STop And Report (STAR) complementing BBSO and SOS

Empowered to Intervene and

Report

• Suggestion & find-and-report schemes for facilities integrity and reliability

• Prompt and positive response from senior management made possible

Platform for Suggestion and

Feedback

Speak Out for Safety Speak Out for Safety

Make our ideas work

4. Management to take Lead – Top-down and Bottom-up (cont’d)

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Transformation to Total Workplace Safety and Health

1. Introduction 2. Management Ownership 3. Management must have Holistic Action Plans 4. Management to take Lead – Top-down and

Bottom-up 5. Workplace Safety and Health Programmes 6. bizSAFE initiatives 7. Conclusion

Source: butterfly - website

5. Workplace Safety and Health Programmes

22 Source: PCS

Core Safety & Health

Programmes

Behaviour Based Safety Observation

STop-And-Report

Speak Out for Safety

Near Miss Report

Suggestion Scheme

Speak Out for Safety Speak Out for Safety

Make our ideas work

The Heinrich 300-29-1 Model

Sense of Vulnerability – zeal to continuous improvement

23 Source: sketches - website

Uncover • Potential

Black Swan Events

Pathway known

• Black Swan becomes White Swan

Challenge • Ensure

Swan remains White

Eliminate Black Swan Events

[Black swan events are typically random and are unexpected] [“Surviving the black swan, strategies for process safety…”, John F. Murphy]

5. Workplace Safety and Health Programmes (cont’d)

In-situ Risk Assessment

24 Source: MHA / website

5. Workplace Safety and Health Programmes (cont’d)

In-situ Risk Assessment

STAY ALERT ● STAY UNITED ● STAY STRONG

Actively prepared workforce • Attentive to unusual activities • Extreme behaviours with staff and workers • Equip with CPR first aid skills, learn IFAS (improvised first

aid skills) • Know Run-Hide-Tell

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Transformation to Total Workplace Safety and Health

1. Introduction 2. Management Ownership 3. Management must have Holistic Action Plans 4. Management to take Lead – Top-down and

Bottom-up 5. Workplace Safety and Health Programmes 6. bizSAFE initiatives 7. Conclusion

Source: butterfly - website

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6. bizSAFE initiatives 28 In-house Contractors; many since

1980s

2001 PCCA Formation;

2004 Restructured

2011 bizSAFE Mentor

Min bizSAFE Level 3; most

at Level Star, 3 at Partner

Petrochemical Complex Contractors Association (PCCA)

Collaboration – unite Contractors companies

Self-regulating – challenge: healthy and safe workplace

Manage ATO – train workforce for HSE excellence

PCS safety culture sink roots – workers take ownership

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6. bizSAFE initiatives (cont’d)

All-inclusive Partnership

Contractors

association PCCA managing ATO

Sponsor core group for external WSH training and seminars

Joint team in external events

Levelling-up

Competency training on work skills, WSH skills and basic language skills (English)

Engaging Contractors on WSH culture building (CultureSAFE)

Capability Building

Monthly training sessions, sharing incident lessons learnt

Monthly Mass Tool Box meeting

Engagement / communication

Management Commitment

Quarterly dialogue with

Contractors Management

Annual Contractors’ HSE meeting with Contractors Senior Management

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Transformation to Total Workplace Safety and Health

1. Introduction 2. Management Ownership 3. Management must have Holistic Action Plans 4. Management to take Lead – Top-down and

Bottom-up 5. Workplace Safety and Health Programmes 6. bizSAFE initiatives 7. Conclusion

Source: butterfly - website

Conclusion – Takeaways • Management take Ownership / Responsibility • Exercise Hierarchy of Risk Control • Tap industry’s Best Practices • Provide Top-down and Bottom-up Two way

Communication • Entire workforce: “I want Myself Safe”

“Timely major transformation strategy to breakthrough vulnerable situation for Total Workplace Safety and Health excellence.”

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THANK YOU

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bizSAFE Convention 2017 14 February 2017 MAX Atria, Singapore Expo Convention & Exhibition Centre

Source: butterfly - website