Our Human Factor Engineering (HFE) approach provides comprehensive HFE support in asset-intensive industries to eliminate or mitigate hazards, failures and financial losses from human error. We have implemented 137 interventions in Human Factor Engineering, including Human Factor Analysis, Human Reliability Analysis, Situational Awareness Studies and Human Performance, Perception and Cognitive Studies. Most of our involvement in this domain has been in Behaviour Based Safety (BBS).
The behavioural-based safety process uses a continuous improvement process based on observations and positive feedback to pinpoint at risk behaviours and weaknesses in management systems. Thus, whereas HFE’s goal is to build a work environment that is as safe as practical, the behavioural-based safety process tackles the difficult task of identifying and rectifying bad habits and gaps in management systems with the ultimate goal of creating a safety culture that supports safe behaviours.
IRCA Global has a long-standing relationship with Arcelor Mittal and we embarked on the large scale and successful implementation of a BBS process for the Client at Galati in Romania.
Client: Arcelor Mittal Steel, Galati, Romania
Size of workforce: 20,000 employees
Project Duration: 18 months
Project Description: Implementation of fully fledged BBS/HFE process, including a 5S intervention and transformational leadership initiative
BBS Project Deliverables
Deliverable 1: Management of Logistics
Deliverable 2: BBS Management and Process Champion Training
Deliverable 3: Visible Felt Leadership
Deliverable 4: Perception Survey / Site Assessment
Deliverable 5: Baseline Observations
Deliverable 6: Supervisor Training
Deliverable 7: Employee PACT Agreements
Deliverable 8: Process Audits
Size / Scope: 20,000 employees working 3 million man hours per month
Number of LTI’s Before Intervention: Average of 16 per month
Number of LTI’s Post Intervention: 26 month no LTI’s in period after implementation
Number of Fatalities Before Intervention: Average 15 per annum
Number of Fatalities After Intervention: Reduced to 2 the year thereafter
Size of BBS Team: 1 Project Director; 4 Senior BBS Consultants and 15 BBS Consultants (Implementers)