Health and Safety principles Ludwig Berger, Director Health, and Safety and Environment Monier Group R O O F S F O R L I V I N G
Key facts 2008 Sales 1,506 million euros Employees 11,155 Sites* 152 in 34 countries Business activities 46 countries * Excluding Associates Group presentation – July 2009 R O O F S F O R L I V I N G Page No. 2
MONIER products Roof Components Roof Chimney tiles Systems systems Low Pitch Ceramic & Steel Concrete, Clay Underlays/Insulation chimneys & Metal tiles Cool Roof Roof outlets/ Ventilation Fittings Snow & Safety System systems Guarantees Ridge & Hip/ Fireplaces Abutments, Eaves Roof packages Gutters, Valleys, Skylights, Solar, R O O F S F O R L I V I N G Fixings
Worldwide network of production sites Americas Europe Africa Asia Group presentation – July 2009 R O O F S F O R L I V I N G Page No. 4
MONIER sites: total 210 • Concrete roof tile plants 122 • Clay roof tile plants 22 • Chimney plants 23 • Aluminium foundry 1 • Tool shops 1 • Roofing components plants 6 – Plastic processing – Metal processing – Underlay production • Other sites/warehouses 23 R O O F S F O R L I V I N G
Monier H&S Roadmap Living Safety Building World Class Foundations 1. H&S Policy and Rules 1. Incident Investigation 2. Mandatory Group Standards in updated 2. Risk Assessment H&S Management system 3. H&S Committees on BU and Site level – Governance Standards 4. Safety Dialog – Operations Standards 5. Auditing and inspection 3. H&S in Management Cycle & 6. Team-based safety Leadership Investment 4. H&S in HR: progressive discipline policy & Accountability 5. H&S Group Steering Committee 1. Sponsorship from the Top 2. Visible Felt leadership 3. Clear Line Accountability for Implementation, 1. Continuous improvement 1. Effective Communication Communication and – Drive roadmap implementation at BU 2. H&S Skills Compliance and site level – Leaders & managers training – BU H&S improvement plan – Supervisors training 2. Safety Measurement and Reporting – Operators training – Group database 3. Capable & Recognized H&S Staff – Incident pyramid 4. Good Practices sharing – proactive and leading indicators 3. Contractor Management 4. Health: Dust, noise …. Learning and Sharing Sustaining Local Improvement R O O F S F O R L I V I N G
LTIFR Trend Q1 2009 18 Quarterly LTIFR 17 Yearly Target 16 Trend 15 14 13 12 11 10 9 8 LTIFR Target 5,91 7 LTIFR Target 5,46 6 LTIFR Target 3,61 5 LTIFR Target 3,25 4 3 2 1 0 Q104 Q204 Q304 Q404 Q105 Q205 Q305 Q405 Q106 Q206 Q306 Q406 Q107 Q207 Q307 Q407 Q108 Q208 Q308 Q408 Q109 Q209 Q309 Q409 R O O F S F O R L I V I N G
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Other Monier H&S tools • H&S mandatory standards – Reporting and investigation – PPE – Working at height – Energy isolation – System audits • Annual safety objectives of each business units – Performance plans • H&S intranet – Accident data base – Accident analysis tools • Training DVDs from our industry • Monier H&S committee (6 members from key BUs) – 2 annual meetings – Monthly confcalls • KPIs monthly reports – Accident alerts – Good practice communication R O O F S F O R L I V I N G
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Prevention of hand injuries program The aim of the program Status 10.12.07 Key elements of the program: • Increasing the awareness for the hazards • Enforcing a team-based safety approach • Sharing good ideas • Enforcing the inspection process R O O F S F O R L I V I N G
The posters R O O F S F O R L I V I N G
Monier Health & Safety Roadmap Living Safety Building World Class Foundations 1. H&S Policy and Rules 1. Incident Investigation 2. Mandatory Group Standards in updated 2. Risk Assessment H&S Management system 3. H&S Committees on BU and Site level – Governance Standards 4. Safety Dialog – Operations Standards 5. Auditing and inspection 3. H&S in Management Cycle & 6. Team-based safety Leadership Investment 4. H&S in HR: progressive discipline policy & Accountability 5. H&S Group Steering Committee 1. Sponsorship from the Top 2. Visible Felt leadership 3. Clear Line Accountability for Implementation, 1. Continuous improvement 1. Effective Communication Communication and – Drive roadmap implementation at BU 2. H&S Skills Compliance and site level – Leaders & managers training – BU H&S improvement plan – Supervisors training 2. Safety Measurement and Reporting – Operators training – Group database 3. Capable & Recognized H&S Staff – Incident pyramid 4. Good Practices sharing – proactive and leading indicators 3. Contractor Management 4. Health: Dust, noise …. Learning and Sharing Sustaining Local Improvement R O O F S F O R L I V I N G
Safety Programs for H&S improvement in the BU´s Objective: Implemented and practiced in all BU´s in 2009 if not already in place 1. Implement Safety dialogue program (unsafe behaviour) • Between BU executive Committee and senior management and shop floor level • Between plant managers and shop floor level • Between supervisors and shop floor level 2. Implement targeted inspection program in all plants/sites (unsafe conditions) 3. Investigate at least all LTI with Monier Standard fishbone method or equivalent method R O O F S F O R L I V I N G
1. SAFETY DIALOGUES (proactive method) Expectation: Each BU has a Safety dialog program for managers which is followed up with a plan. Principles of Safety dialogs • Improving safe behaviour and influence unsafe behaviour by regular safety dialogues • Checking the implemented behavioural safety rules • Understanding why do employees behave safe or unsafe • Demonstrating sponsorship and accountability • Understanding importance of good examples and visible felt leadership • Improvement of H&S culture • Dialogs are documented and followed (NM) (NM) (NM) (NM) up with a plan UNSAFE BEHAVIOUR UNSAFE BEHAVIOUR R O O F S F O R L I V I N G
Method of Safety dialogues Safety dialogue between superiors and employees „Top down“ The three levels of Safety dialogues 1. Executive board and shop floor employees – Top management is setting strong signals for the importance of safety 2. Plant/ site manager and shop floor employees – Plant/ site manager shows leadership and influences general behaviour 3. Supervisors, shift leaders, team leaders and shop floor employees – Direct superiors are in close contact to employees and influence behaviour directly • Time consume per dialogue: 15 min R O O F S F O R L I V I N G
Example of Safety dialogue planning for BU Who: Function Where: Location of With whom: one When: Date of Protocol/ Responsibility Safety dialogue to one Safety dialogue Documente Business Unit Executive Executive board board member and employee Hugo Boss CEO Manheim plant Operator Plant visit: April 2009 Production Peter Zapf Marketing Stockholm plant Operator, packaging Plant visit: January Director Logistic Dispatch worker 2009 Heidi Klum HR Director Stockton plant Supervisor Plant visit: February Dispatch 2009 Plant manager Plant/site Plant manager and employee Johan Plumber Plant manager Monheim plant, production Operator Week 3, plant tour Monheim Monheim plant, paint shop Fork lift driver Week 4, plant tour Monheim plant, accessories Operator Week 5, plant tour ...................... Perry Rodan Plant manager Hamburg plant, production Mixer operator Week 3, plant tour Hamburg Hamburg plant, paint mixing Operator Week 4, plant tour Hamburg plant, accessories Supervisor Week 5, plant tour ........................ Supervisor Department in Supervisor level and employee plant/site Uwe Seeler Supervisor Stockton plant, production Operator 1 By situation but Operator 2 documented Operator 3 ...................... Many Neumann Team leader Stockton plant, accessories Operator 1 By situation but Operator 2 documented ...................... Operator 3 Herrman Shift leader Stockton plant, mixing Operator 1 By situation but Hinterberner department Operator 2 documented Operator 3 ............................. R O O F S F O R L I V I N G
2. TARGETED INSPECTIONS (proactive method) Expectation: Each plant has a system for targeted inspections which is followed up by a inspection plan. Principles of targeted inspections • Site inspections structured by important safety topics: – One topic at the time – Use prepared checklists for each topic • Check the implementation of Monier standards (WAH, PPE) • Find unsafe conditions • Findings are documented and followed up and rectified • Distribute the responsibility on several persons • Minimise time consume and maximise effect (NM) (NM) (NM) (NM) UNSAFE CONDITIONS UNSAFE CONDITIONS • Time consume per inspection: 30-45 min R O O F S F O R L I V I N G
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