Improving Employee Hazard
Recognition
Cory McBride-Curt Krambeer
International Paper
Cedar River Mill
Cedar Rapids, IA
Cedar River Mill
• Largest 100% recycle-based paper mill in
western hemisphere
• Two paper machines
• Work force of 220 team members
• We produce brown paper for boxes
Cedar River Mill
SAFETY VISION
Everyone enjoying a superior quality of life
Unsurpassed personal commitment to the
safety, health, and well-being of self, family,
friends, and community.
Awareness – Attitude - Action
• Do we automatically
know about the
“Golden Poison Frogs”
in our work places?
• Everyone’s hazard
recognition abilities will
need a little help.
Our Message
• Communication
• Communication
• Communication
Further:
• Build Systems of
Communications
Training
• Training for new team members
– General safety training
– Overview and specifics on safety processes
– Overview of papermaking and related hazards
Some Topics for New Hires
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General Safety Rules
Lockout-ZES
Confined Space
Hazard Communication
Hot Work
Stop Program
Safe Start
• Chemicals
• Rigging
• Environmental
Concerns
• Behavior-Based Safety
• Papermaking Process
• Housekeeping
Classroom training for new hires
• Permitted processes are
covered in classroom
settings
• Electrical training is
included
Lockout Board for #2 Dry End
• After covering topics in the classroom,
trainees are able to see processes used on the
operating floor.
Training for Specific Job Skills
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Raw Materials
Shipping
Winder
Stock Prep
Wet End Paper Machine
Dry End Paper Machine
Control Room
Training
• Training for job skills
– Task training including job hazards
– Assisted time and unassisted time
– Standard procedures that include hazard listing
Training Checklist
• Checklists for Job Skills include all SOP’s
related to that particular job and contain
safety items that the trainer and trainee must
review and initial.
Winder Checklist
• Seven pages of items (safety aspects, standard
procedures, known hazards) that must be
reviewed by trainers with all trainees.
Standard Operating Procedures
• SOP’s are step-by-step flow charts showing
reliable methods for completing tasks
• Warning boxes show hazards that need to be
avoided during tasks
On-The-Job Risk Assessments
• Job Performance Safety Analysis
– Group discussion of project or task
• Pocket Cards
– Individual-based reminder card
• Behavior-Based Safety Observations
– One-on-one discussions
• Vehicle/Crane/Tool Inspections
– Looking for hazards every shift
Team Members Help with Audits
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VPP Audits
Key Element Survey Audits
Wall-To-Wall Conditions Audits
Winder Audits
Housekeeping Audits
Mill-Wide Communications
• Incident Flashes
– Documented within 24 hours of incident
– Distributed using several modes
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Email
Morning leadership meetings
Bulletin Boards
Preshift meetings for process and maintenance teams
Entered in database for corporate distribution
Incident Flashes
• One page document to show what, when, and
where
• Printed on yellow paper and posted in main
hallway
• Lists immediate corrective actions to be taken
• Does not include names of people involved in
incident
• How & why determined in investigations
• Incident Investigations
– Conducted by trained team members
– Reports distributed as widely as flashes
– Significant investigations include power point
presentation for quicker & easier description of
incident as well as communicating root causes and
corrective actions company wide
Corrective Actions
Action
Responsibility
Completion Date
Follow up with carrier to ensure all
drivers are receiving proper training
and safety information
John Doe
4/15/13
Per IP policy, driver banned from mill
site for 24 hours.
John Doe
3/29/13
Meet with carrier to discuss incident.
Jane Doe
4/12/13
Share incident with all carriers.
Jane Doe
4/12/13
• Contractor Meetings
– Monthly meetings with on-site contractors
– Quarterly meetings with safety and leadership
representatives from all contractors
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Held the day before a major maintenance outage
Review of safety performance
Review policies and procedures
Discuss changes and updates on hazard prevention
• A Wide Variety of Visuals
– Posters and Bulletin Boards
– Hazard labels
– Warning signs
– Danger & caution tape with barricade tags
– Yellow paint on steps
– Black and yellow floor stripes near winder
– Stripes for crane use near reel
EHS&S
February 21, 2013
In 2010 International Paper launched the
LIFE initiative, a multi-year effort to
identify and mitigate the potential
hazards and risks that lead to serious
injuries and fatalities.
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LIFE Definition
What is a LIFE Incident?
A fatality or amputation
OR
An injury that results in 14 or more calendar days away from work and involves:
• Organ Damage
• Concussion or Other Brain Trauma
• Bone Fracture
• Crushing Injury
• Degloving
• Serious 2nd or 3rd Degree Burn
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2012 LIFE Incidents
2012 Employee LIFE Incidents
Machine Safeguarding
Falls
23%
28%
Motorized Equipment
23%
18%
10%
Other*
Harmful Substances or
Environments
Driver Safety
*Other – Primarily struck by or
caught between objects
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LIFE Lessons
• One-page summaries of LIFE incidents are
shared among company sites to allow all
employees in International Paper to learn
from each incident.
• A picture, brief summary, root causes, and
corrective actions are included in the lesson.
5 LIFE Focus Areas and
a New Contractor Safety Emphasis
Machine Safeguarding
Motorized Equipment
Falls
Exposure to Harmful Substances
or Environments
Driver Safety
New for 2012
Contractor Safety
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How do we get there?
Identify &
Eliminate
Hazards
Individual
Accountability
Look Out for
Others
Intervene
When Needed
“Management is doing things right;
leadership is doing the right things.”
-Peter Drucker
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Local LIFE Initiative Work
• Traffic flow analysis and controls
• Machine guarding inventory and
improvements
• Cell phone policy implementation
Driver Safety-Cell Phones
Absolutely no cell phone use when driving:
-in company vehicle
-in company-rented vehicle
-in any vehicle on company property
-including any powered industrial truck
-in private vehicle on company business
Her last call was from a cell phone.
Combinations of Hazards
• What do we get when unsafe behavior A
intersects with unsafe behavior B in time and
space?
At an estimated 85 mph, the motorcycle driver could
not react when the automobile driver on a cell phone
pulled out from side street.
More IP employees work safely
today than ever before ...
• Numbers show
downward trend in
recordable injuries
• 70% improvement in
TIR since 2000
• IP leads the paper
industry in safety
• Many facilities are
working injury-free
… but there is more
work to do
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Safety is not about numbers.
It’s about our health and well-being …
it’s about our teammates…
it’s about friends…
It’s about family…
…and our ability to go home safely to them
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