Releasing the Forces for Excellence

safety excellenceAs this year comes to an end, we will be looking at our overall performance to see how we did and to plan for 2017. We will usually look at our injury statistics like the total recordable injury rate and try to determine how we performed. Often quite independently, others will look at other performance indicators to see how they came out. We act as if these are independent of each other, but in our organizations everything is connected so all aspects of performance influence each other. Everything happens through the people. All the parts are interconnected. Excellence in safety performance is strongly related to our total performance because it all works through the will of the people.

We traditionally try to apply safety and other metrics to our organizations in a machine-like fashion. We see that something needs to improve so we push harder as if we are pushing a wagon up hill. Too many regulators and managers sit in their offices trying to imagine what needs to be done and write a new procedure or rule so that things will be better. Then they issue edicts pushing everyone harder. However, the work as imagined is never the same as the work as done. Why do managers think that sitting, bound to their office chairs, that they know everything? How can they? Then at the end of 2017 we will do this all over again trying to understand why things did not get better. Around and around we go!

We break this vicious cycle by opening up ourselves to a different way of thinking, seeing and being.

safety managementWork-as-imagined and work-as-done are ideas developed by Erik Hollnagel in his book, Safety-I and Safety-II (2014. Ashgate Publishing Ltd., UK). Safety I is our traditional top-down management approach to safety management where rules and procedures are issued by those far from the actual work. This is like the approach discussed in the proceeding paragraph. I think that a lot of people are trying to do good safety work from the Safety I perspective, but the results are not improving fast enough.

For example, the Bureau of Labor Statistics (BLS) recently reported that the rate for nonfatal injuries and illnesses per 100 people dropped to 3.0 in 2015 from 3.2 in 2014 and 3.3 in 2013. That is a 10% drop over three years. That is way too slow! In 2015 2,900,000 injuries were reported. That is WAY TOO MANY people getting hurt. In an earlier paper the BLS reported that the number of fatalities has hovered around 4,700 people a year for the last 5 years. This is WAY TOO MANY!

This is not just a US problem. For example, Worksafe, New Zealand recently reported that the health and safety laws have had little effect on reducing fatalities further.

While driving safety from the top has had benefits historically, the effort is having less and less impact. But when we change our approach to working with the people to co-create our future, things change for the better quite quickly. This is true! It’s proven!

In the work of Richard N. Knowles and Associates, we approach the organization as if it is a living organism. Time after time coming out of our Safety Excellence Workshops, the performance improves quickly. When we engage with the people this way and help them to co-create their safety future, building on the positive strengths of the people, safety and all other aspects of their work get better quickly. For example, when I was the Plant Manager at the DuPont Belle Plant in West Virginia we worked this way, and our injury rates dropped by over 95% and earnings rose 300% in just three years. This is similar to Hollnagel’s Safety II approach.

Whenever we, at Richard N. Knowles Associates, work in organizations the safety and total performance improves quickly. Everything happens through the force of the will of the people. We release this force helping the people to co-create their shared future. Then we show them how to sustain their work for the years ahead. All dimensions of the business improve; costs are lower, productivity is higher, morale is better and far more people are working safely.

Call us at 716-622-6467 so you can release the positive, creative forces in your organizations quickly!

When the Safety is Right, Everything Else gets Right!

I recently read a book by Steve Zaffron and Dave Logan, The Three Laws of Performance. They have studied leadership in many organizations and developed Three Laws of Performance and three Leadership Corollaries for these (P.212).

The First Law
How people perform correlates to how situations occur to them.
Leadership Corollary 1
Leaders have a say, and give others a say, in how situations occur.

The Second Law

How a situation occurs arises in language
Leadership Corollary 2
Leaders master the conversational environment.

The Third Law
Future-based language transforms how situations occur to people.
Leadership Corollary 3
Leaders listen for the future of their organization.

These three Laws and Corollaries are almost identical to what we do in Self-Organizing Leadership as we use the Process Enneagram© with the people. In using this tool in conversations with the people we co-create the future with everyone having a say in it. We spend a lot of time in the organizations talking with and listening to the people seeking new and better ways to do things.

For some people in leadership positions, talking with people, seems to be quite hard. Yet it is as simple as for example;

“Hi Mary, How are things going today? I hope everything is going well on the home front. You look like you really know how to do this task. I’ve never done it before, could you show me how you do it? What are the safety challenges and rules? Is there a better way to do this? Is there an easier way? Let’s talk about that. If I help you, can you take the lead to develop the idea and see if it really works as well as you think?”

This conversation shows how the Three Laws of Performance play out. Mary usually gets pretty pumped up as she is listened to, respected and asked for a better, safer way. This may be the first time she’s been treated this way by management.

As this simple interaction occurs, over and over throughout the organization, the culture shifts to becoming more positive, resourceful and creative. When the people see that management is really listening and trying, when they see the manager as real people things open up. Ideas about things beyond the safety arena emerge and big savings develop for the company.

When I was the Plant Manager at the DuPont Belle, WV Plant, working this way with about 1,200 people we made huge changes that endured for many years. For example, injury rates dropped >96%, emissions dropped 88%, productivity rose 45% and earnings rose 300%. Together we achieved world-class safety performanece with total recordable injury rates running at 0.3 or less. They maintained this excellent performance for 12 years after I left for another DuPont assignment.

Zaffron and Logan have a case study in their book about New Zealand Steel near Auckland, New Zealand. The mill was struggling and the management decided that they really needed to change the culture to survive and grow into their future. In just 2 years New Zealand Steel transformed themselves. Injury rates dropped 50%, productivity rose 20%, costs dropped 15-20% and return on capital rose 50%.

As I was reading the story I realized that I knew the people they’d named and that Tim Dalmau, my associate in this work, and I had led the transformational effort using the Self-Organizing Leadership approach. The Process Enneagram© was the key tool we used to help the people have the important conversations and discover their future.

These two stories of the transformations of the DuPont chemical plant in Belle, WV and the New Zealand Steel plant in Auckland, New Zealand clearly show that the work with the people to shift the safety culture is the leading edge of change for the entire organization.

What the West Texas Disaster Can Teach Us

Wednesday evening, April 17, 2013, there was a terrible explosion in the West Fertilizer Company’s fertilizer plant in Texas. The latest reports indicate as many as 14 people were killed and over 160 injured.

The plant was located right in the middle of the town of 2,700 people and the explosion caused a huge amount of physical destruction in addition to the human devastation.

The plant handled ammonia and ammonium nitrate for fertilizer use.

These are well-known, hazardous materials that can be, and are, handled safely by most companies. There is extensive process safety technology regarding the handling and use of these materials. The technology applying to these materials as with many chemicals is strong and effective.

There are two major dimensions to using, making and handling hazardous materials. One is the process safety side, which is well known and effective, and the other side relates to the way the people choose to work with these materials, and choose to use the technology. The best process safety in the world is of no use if people don’t apply themselves and use the process.

In 2006, according to the Dallas Morning News, the Company was fined $2,300 for failure to have a risk assessment. In one EPA report they said that they handled anhydrous ammonia assuring them that no one would get hurt in the event of a release.

While we do not know specifically what happened, my many years of experience in managing chemical plants, would suggest to me that these are indications that the people side of their systems failed in some way. These are hazardous materials that need to be handled with professionalism, dedication and attention to procedures.

The lesson to be learned here is to rethink your situations in your own factories, plants and businesses where you handle and use hazardous materials. Think about questions like:

  • Do you talk together and share safety information?
  • Do managers get out of their offices and into the operating area to talk with the people on the floor?
  • Is the level of trust high enough that employees will freely report safety concerns and near misses?
  • Des everyone work together to solve safety problems?
  • Are your Material Safety Data Sheets and Safety manuals up to date and used?
  • Are employees properly trained and is the training schedule maintained?
  • Do you have high housekeeping standards and are your facilities properly maintained?
  • Do your employees have the resources they need to work safely?
  • Are you cutting corners to speed up the operation?
  • Do people have the proper personal protective equipment and do they use it?
  • Do you have a system of follow-up so that suggestions can be implemented quickly?
  • Are people able to shutdown a process on their own if it is unsafe?
  • Can people refuse to do a job if it can’t be done safely?

The questions can go on and on, this list barely hits the surface in what can be addressed when making a commitment to safety in the workplace and having a leadership team where safety is a priority. It takes discipline and hard work to stay on top of safety issues, but these are the kinds of responsibilities and burdens any organization working with and using hazardous materials must bear. If you use these materials, then you must accept the responsibility that comes along with the use. The people in your facility and those living around you depend on you to do your job well.

As a manager of plants handling and using hazardous materials, my mantra was “I don’t have a right to work at a place where it is okay for you to get hurt. Now let’s get the safety right and make money.

What is your safety mantra, your deep, authentic safety message for your people?

As we have seen from this indecent in Texas, the results can affect more than just your plant or business – entire towns can bear the brunt of accidents, explosions and the destruction that follows. My heart goes out to the town, the people, families and the plant workers. Situations like this are preventable…with Safety Leadership that comes from top down.

If you don’t have a safety mantra or message and follow the processes…I strongly recommend you get this in place and FOLLOW IT. Your business and the people that sustain it are depending on your leadership for their safety and the safety of many others.

Safety Excellence for Business

The Goal is Zero sets us up for failure.

None of us wants to have anyone get hurt in our organization. We are trying hard in various ways to keep people from getting hurt. Sometimes organizations can achieve very long periods of injury-free performance. One large plant I know of went 24 years without a lost workday case (LWC), and another one went for about 10 years. These sorts of strings of injury-free days are commendable. This can tempt us into believing that if we just work hard enough that we can achieve workplaces where there are no injuries.

We do indeed have to work hard, but I don’t think that we can ever achieve injury performance forever.  The things that people do or don’t do relating to safety are the cause of over 95% of all injuries. None of us is perfect. Our minds wander. We get into a hurry. We forget something. We get distracted. We are upset by a problem at home or at work. We develop bad habits.

I expect that all of us do something unsafely every day and don’t get hurt. But one day the conditions will be just right for things to come together in a new, different and unexpected way. Then we suffer the consequences.

When management sets the “Goal is Zero” we set ourselves up for failure. There is very strong pressure in most organizations for people to report what management wants to hear. If the “Goal is Zero” then the pressure builds to look for ways to avoid having to report an injury or near miss and the cover-ups begin. People will tend to just report things that are too big to hide. A major source of our safety information disappears. When we don’t report the small things then we can’t learn from them. Problems persist, bad situations are not addressed, and reporting can get a person on the wrong side of their management. Sometimes management creates a reporting system that is so difficult and exposes the person making the report to criticism, that the people just avoid reporting. Trust among the people in the organization is impossible to establish. When trust disappears, learning stops!

In order for trust to be built information needs to be openly available to everyone. The environment needs to be secure enough that we can talk and learn together. We need to help each other becoming our brothers and sisters keepers. Listening and respecting each other is critical.

When management creates a culture of openness, trust and interdependence, and an environment where everyone can see the big picture long periods of injury-free performance can be achieved.

John, a wise friend, told me once  “When the safety gets right, everything gets right!”

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