Document G9d78NGmj7DrREYdbND7JdKN

"SAFE WORKING STYLE" DOW - TEXAS OPERATIONS NEW SAFETY PROCESS Since 1983, Dow's Texas Operations has not SHOWN AN IMPROVEMENT IN ITS TOTAL INJURIES PERFORMANCE. An INTENSE SURVEY WAS MADE THROUGHOUT ITS FACILITIES (OVER 7,000 EMPLOYEES) LOOKING FOR A SYSTEM CHANGE. A CROSS-SECTIONAL GROUP WAS FORMED AND PRODUCED THE SAFE WORKING STYLE PROGRAM. This program addresses the human errors THAT CAUSE OVER 70% OF THE SAFETY incidents. The Safe Working Style concept is Dow's Texas Operations vision of safety OF THE NINETIES. Jack Lippman Safety Director Chlorinated Organic Products & Phenol Dow Chemical U.S.A. Freeport, Texas CTL020571 TEXAS OPERATIONS TOTAL INJURIES HISTORY INJURIES 1200 - 985 1000 - 800- t l 600 *- 985 864 815 400 - 200 - o- 1983 B:HGDATA:IN IHIST 1984 1986 1987 1988 AOM/CH l-ia-A* CTL020572 TEXAS OPERATIONS FACTORS INVOLVED IN OSHA RECORDABLE INJURIES 1988 BEHAVIOR 73% SYSTEM 27% ) CTLo*os73 Safe Working Style Your Individual Responsibility CTL020574 Copyright, 1988 The Dow Chemical Company Safe Working Style Features... Our Goal The goal of Safe Working Style is simple: to improve safety statistics. Our method is straightforward: improve safety statistics by reducing human error in the workplace. Accom plish this through a behaviorally based workshop and follow up program. Human Error Safe Working Style concentrates on our most formidable problem in safety today, human error. Human error has become the greatest cause of accidents in a world where our engineering technology has made our plants safer... more and more reliable and "hazard free." The Best Thinking A program with a goal like this must contain the best thinking and experience in the country... no more, no less. Through brainstorming, surveys, interviews and short cycle empirical tests, our Safe Working Style Committee has pulled together the best from our safety experts and plant experts on the front line of industry. In addition, we have pulled in the knowledge and support of the best researchers in the country, folks like Ken Blanchard in management and organizational research, John Lauber in human error and aviation safety research, and Linda Perloffin psychological research. In the workshop, you will see safety applied through the related expertise within our global community. Tom J. Peters, Robert Watermann, Robert Mackie, Charles Hughes, the late Eric Beme and H. S. Sullivan have given us the vision to see the "Safety ofthe Nineties" and how to work on it. Your employees will experience this vision in a high speed workshop, packaged as a rapid learning device. The following pages list important features of this program. CTL020575 Safe Working Style Features... The Incredible Chain of Events (The ICE Machine!!!) What is the Incredible Chain of Events? Disasters larger than real life, events that we really don't like to think about: the Challenger explosion. Three Mile Island, the crash at Detroit airport, a gas release from a chemical plant Why must we look at events like this? In these very events, subjected to in-depth study, we can find subtle underlying human errors and leam how to prevent them. DmIncredible Chain ofEvents is a chain of human error resulting in a disaster. In the High Pressure Game, we call it the "ICE Machine." If we break one link in the chain by eliminating one of the unsafe components, the ICE Machine will not freeze it's victims. What's the real value of learning the about the Incredible Chain of Events? It will give your employees an idea of their importance in everyday on-the-job interactions. Our One Minute Safety Opera tions, taken from Ken Blanchard's One Minute Manager techniques, lay out definite methods of breaking the chain of human error! CTL020576 Safe Working Style Features... The ICE Link The /ncredible Chain ofEvents consists ofone ormore ICELinks. Each link contains the following: a situation, a safety issue, some type of pressure, and when enough pressure is applied - a High Pressure Response. Closing a link with a High Pressure Response sets up the possibility of another link forming... until an incredible event happens, something totally unexpected by most people. The Challenger Explosion, Three Mile Island, a crash at the Detroit Airport, a gas release from a chemical plant. If we can break one link in the chain by eliminating one of the components, the incredible event will not occur. In Safe Working Style we concentrate mostly on contemporary pressure and the High Pres sure Response components. These are the components least addressed by other safety programs. CTL020577 Safe Working Style Features... --1 ---------------- . ... .s* ' - ,, \ .' t. <* <.v -i> -' *`,.^i '' \ ' 5^Ug --------------- 3 .. . ,,J } !-------- -------rJE srru ^---------\ rv rfl ...... /. <--w---'~>v'----^>TM-...-,'.^.;.i^_,'.;;. The High Pressure Game The High Pressure Game teaches how to deal with the elements of human error found in the Incredible Chain of Events. The Game consists of two phases: Video Models and the High Pressure Board Game. Individual points earned by correctly scoring the Video Models are then used in a team effort to play the board game. During both phases of The High Pressure Game, participants work with life-like ICE Links, just as in real life. CTL020578 Safe Working Style Features... Most points in the High Pressure Game are awarded foridentification ofourthreeclasses of High Pressure Gang Members. The Illusionists, SlipWalkers, an&iheHigh Pres sure Team. Thirteen of these fourteen gang members represent unsafe responses ...ele ments of human error ... eleven are subtle and not so subde High Pressure Responses to contemporary pressure that lead to acci dents, even to an extended accident chain... the building oftheIncredible Chain ofEvents ... the building of an ICE Machine. ^0205*79 Safe Working Stole Features... High Pressure Test Theory! Our High Pressure Test Theory states that High Pressure Responses are due to high pressure. Anytime we crank up the pressure enough, we will get a High Pressure Re sponse (contributing to "human error") at some point. Cranking up the pressure is ex actly what we do in our video models. When we apply enough pressure to situ ations, we get definite responses that we can categorize. Deep seated beliefs about per sonal safety come to the surface. Physical "SlipWalking" occurs at higher pressures and High Pressure Team Responses, such as Job Expert and the Gamester become crystal clear. High Pressure Test Theory explains the relationship ofhuman error and high pressure in a contemporary world. CTL020580 Safe Working Style Features... Pressure and SVpWaBdng, an Example Pressure In the High Pressure Game, ourSlipWalkers comprise one of three groups in our High Pressure Gang. The Absent Minded Confessor and r3d3, normally low pressure char acters, become the Switcher and the Juggler under high pressure. This pressure can come from any number of sources. SlipWalkers, as well as the Illusionists and the High Pressure Team Members show up consistently in our industrial accident investigations. Industrial accident research combined with aviation accident research by John Lauber and others have allowed us to reach a new level of insight into human error and the Incredible Chain of Events. CTL020581 Safe Working Style >' ss ' ?*Avw- , ' ^' ' .. w.y CTL020582 Illusionists Feels vulnerable. Knows there is risk in everything. Takes precautions. Typical Statements: "Okay, let's look at the risk again." "Listen to her/him, that may be a good idea!" SWS Realist Whodini Has taken precautions in the past, now feels invulnerable. Typical statements: "I fixed that problem a long time ago." "We studied this procedure many times in the beginning." 007.5 Has not taken safety precautions but feels invulnerable. Typical statements: "It can't happen to me!" "I'm not the average person!" CTL020583 SlipWalkers Due to forgetfulness, concentrating on one item, not enough pressure or reminders; ... Forgetting for no reason. ... Forgetting a name. ... Forgetting your reminder! Due to an interruption: ..Jailing to finish a job. ...Losing your place. ...Omitting a step. ...Switching attention to something not as important therefore mining a hazard. Absent Minded Confessor The Switcher Due to learned actions placed on automatic ... Automatically performing an unintended complete sequence. ... Robotically reading a gage or instrument and "seeing" wron: reading. ... Having no recollection of what you just did. ... Getting that "What am I doing here?" feeling. r3d3 Due to speeding up: ... Hitting wrong switch or buttron. ... Reversing objects being worked on. ... Picking up wrong object ... Reading wrong gage. The Juggler CTL020584 The High Pressure Team macho job expert "Don't tell me! I know how to do this job best I'm not open to ideas/suggestions." Groupee "I'm just going along with (Expert/Comfort/Gamestcr/ Harried Time Manager). -<x- Gamester "Yes, but___ "I can't because. "Look whai you made me do!!! Smooth Student "I forgot! "Tell me again. "I didn't know!" Harried Time Manager "We've got to huny due to Statistician "Who can really prove that_____ is safer???" CTL020585 GlobeZilla The monster of international competition and comtemporary pressure. GlobeZilla adds pressure from 1000 angles. It's easy to find him increasing job pressure, team pressure, and personal pressure. GlobeZilla has become the "time management monkey" for the nineties and has begun driving the Harried Tune Manager, which is an unsafe response to pressure showing up in our work teams. GlobeZilla is often the underlying force behind pressures which evoke the other unsafe responses such as Macho Job Expert and the Juggler. We cannot eliminate GlobeZilla. However, we must maintain high vigilance and realize that this is the driving force behind the pressure in many Incredible Ghaim of Events. CTL020586