We always hope that the problems we have already encountered will not be repeated next year, but unfortunately reality shows otherwise. What we see is that as soon as a task becomes routine, our concentration decreases and our carelessness increases until we are shaken by an event that could be even fatal. Unfortunately, this was the typical rutine in 2023.
One of the foundations of the accident prevention strategy is to first analyze the main causes of accidents in recent years, and then use the results to identify the measures (e.g. increased control of wearing cut-resistant gloves) and focus points (e.g. new employees, most accident-prone departments, safe elimination of defects) that need to be taken in the future. It is important to monitor accident statistics continuously, as they show the effectiveness of the measures introduced, i.e. whether the number of accidents and their severity is decreasing. In accident prevention, it is difficult not only to achieve results but also to maintain them. Our experience is that when we start working together with colleagues to address the causes of an accident, we succeed in reducing the number of accidents to zero! It may seem unbelievable, but we have had several years when there were no accidents involving sick leave at the most dangerous processes – mixing, extruding – but the same could be said for cutting accidents. This also shows that it is possible to achieve a “zero” accident level, but we have to work continuously and collectively to maintain it.
As in previous years, we started the year 2023 with education, with each workshop providing everyone with an insight into the accident risks and prevention rules in their respective areas. The focus was on the dangerous aspects of the worker and his or her work, which require increased attention and compliance. This series of training sessions immediately produced measurable results, as there were two months in which there were no incapacity accidents and the first six months were characterized by low accident rates. However, in the remaining months of the year, there were unusual incidents with complex problems, resulting from inadequate situation assessment and recognition and inadequately evaluated risks.
New situations can bring new dangers
Take, for example, the case where a colleague on a conveyor belt 3 meters long has to roll up a rubber sheet by hand in a given time, cut it off the belt with a knife and form a stack. When this colleague is giving practical training to a new entrant, the two of them stand by the belt and share the work. You might think that with two people the process is even easier, but that is far from the case. For an inexperienced colleague, a section of a moving tape that is only 1.5 meters, is not enough space to do the job safely. When training new colleagues, increased attention is required, both in terms of the operation of the machine and the hazards of the environment.
Based on the experience of the accidents of the past year, the following facts and rules can be formulated:
- Safety is above all else, and you must immediately react if anything could put your safety at risk. Any change that could create a real danger must be rejected. When there is even a little bit of a reversal of priorities that could take the focus away from safe working, you must react immediately.
- Hiding problems can be the cause of a serious accident later! Individual responsibility is very important, there is no excuse for this. If a previously established process cannot be applied to a problem, a new process must be developed, trained and implemented in consultation with the people involved. There is a solution for everything!
- Safety is a community interest, a pillar of the community! We heard very good examples of how the shifts of some processes have introduced “internal” measures and communication channels to identify and manage hazards. However, it is important to know that all safety-related procedures must be approved by the EHS Team.
- The safe steps and their requirements for hazardous work processes must be set out in writing. Training on the rules should be organized for those working in the field and the lessons learnt should be followed by colleagues. Only the written, approved method can be required to follow.
- Adapt to change and manage it with a risk-based approach. When changes are introduced (new working methods, new machines, modified machine operation, new colleagues, extra workload, etc.), new hazards may arise and new measures may need to be introduced. This has to be always considered.
Make your everyday life safer at work and in your private life!
We wish everyone accident-free work!