3 TPM Safety

ULI SAFETY VISION & PRINCIPLES

1

ULI Safety Vision & Principles

Vision:

”T b id f i i h h b dd d f”To be an accident‐free organization through embedded safety culture in our daily life”

Values/Principles:

All accidents are preventable  

Safety is everybody’s responsibilitySafety is everybody s responsibility

Learn, think and act safely for yourself, family and other people around you 

Safe working condition, awareness and care, lead to accident free

Safety is a foundation for business continuity

2

Safety in Unilever Indonesia

Objective :

To prevent any loss of 

People

Environment

A tAsset

Reputation

within the scope of Unilever responsibility & accountability on any

Unilever business.

In short: ZERO Accident

3

Safety in TPM

4

What is Safety?“Peaceful condition free from danger of accidents, particularly danger leading to human death or casualties”

Designing Safety , Jiro Abeg g y ,

Safety is the maintenance of peace of mind

<Effects>

Target = “Maintenance of peace of mind”

<Effects><Effects>Degree of social effects (small)

<Effects>Degree of social effects (great)

<Range>

Safety andHealthMgmt

Environmentalmanagement

<Range>Human beings who have directinterest in target objects(Management, employees, and shareholders)

<Range>Human beings who do not havedirect interests in target objects(nearby residents,general consumers, etc.)

5

Safety Scope

Offices (HO, Mendut, MBAU, MMLC)

3rd Manufs

3rd P SHE Standard

Depo WHDepo WH

Depo WHFull FS CS-SHE 3rd P SHE/Aerosol

ManufacturingSupplier Transfer Transfer CDC Distributor

Customer

Area of Responsibility

A f I fl CustomerArea of Influence

6

Embedded in ONE SYSTEMOHSAS 18001 – Occupational Health and SafetyISO 14001 - Environment

7

Accident Causation

8

2 Approaches To Safety Activity

9

TPM Safety Activities

10

TPM Safety Activities

11

TPM Safety Activities

12

13

Th W W D SAFETYThe Way We Do SAFETYin Unilever Indonesia

14

Good Safety is Good Business

Chairman addressing the importancy of safety among others business points in his presentation

420 Distributors & Business Partners & 275 ULI CD Management giving attention during safety session

15Bad side of safety is presenting in the form of “opperette”, live & giving direct emotional impact

A National Public Speaker (Management Guru) & Unilever Safety Manager, side by side giving safety talks show to the audience

Exhibit Leadership Commitment

HR VP discussing the sufficientcy of guard at

CD VP Found unsufficient guard for a working steps

warehouse

16

Exhibit Leadership Commitment

Chairman ULI did safety contact with employee-biker

Foods Marketing VP & other VP did safety contact with other biker

17

Chairman ULI deliver safety speech to all employee across the nation (live broadcast). Chairman ULI having discussion on

pick-up shuttle implementation progress

Weekly Safety TalkWh t it i• What it is:

– A sharing session on safety

– A cross the organization

– 15 minutes15 minutes

– Lead by unit leaders, but speaker could be the team member

– Done in weekly basis (ussualy in Friday)

– recorded

18Safety talk at Depo Medan, May 2008

Travel Safety Activity

Safety Defensive DrivingSDD 2 wheelers : 832 employeesSDD 4 wheelers : 80 employees

Transportasi Truk

TheoryMacet Ganjal

Pintu macet

terangkatBan gupilJoin rusak

Join lepas

Macet

Unsafe act

Pick Up ServiceIsi check list

mandiri

Checkikan

Unsafe Act & Unsafe ConditionPick Up Service•12 minibus (180 seats/shift) available•9 Favourite Routes Established

Practice

Check Security

Stand

Perb

ai

Fork Lift Safety

StickerSafety

Berlaku6 bulan

19

Fork Lift SafetyRoutine Deep compliance Audit as

part of SBO on-line

Tahun 2007 berhasil mengurangiIncident truk dalam pabrik

Participating in Government CampaignP l S di J l R d l h di K li i S b d J PPelopor Santun di Jalan Raya adalah acara yg di gagas Kepolisian Surabaya dan Jawa Pos, melibatkan beberapa perusahaan yang dinilai komit untuk membantu menciptakan jalan rayayang lebih aman. Unilever termasuk perusahaan pelopor dengan memastikan karyawanpengguna motor telah mendapatkan Training Defensive Riding sejak thn 2007.

Komitmen bersama: Kepolision, Chairman & karyawan ULIuntuk jalan raya yang lebih aman

Pelepasan karyawan pelopor Santun di Jalan RayaOleh Chairman ULI

20 Penghargaan untuk Unilever site Rungkut dari Kepolisian Surabaya

Karyawan ULI dengan helm standar daru perusahaan

Road Safety Tips

21

Unilever Indonesia Road Safety Rules

22

Unilever Indonesia Road Safety Rules

23

ULI Road Safety Cardinal Rules 

Rule #2

a) Wear safety seat belt for driver and any passenger (car)a) Wear safety seat belt for driver and any passenger (car)

Rule # 4,

Don’t Drink and Drive

Rule #6

Engine on, no mobile phone

24

Lomba Ketangkasan SafetyLombaMengenakanFire Jacket

L bLombaMengenakanB.Aparatus

LombaMengenakanJas Anti Kimia

25

Lomba Ketangkasan SafetyLomba P3K

26

Lomba Ketangkasan SafetyPemadamanDenganKarung Basah

PemadamanDenganAPAR

PemadamanPemadamanDenganHydrant

27

Fire Evacuation Drill

Floor berusaha memadamkan api

Fungsi alarm yg bekerja baik

Team Pemadam Sangu menuju TKP

Menuju assembly point melalui tangga darurat

28Di assembly point dan Floor coodinatormelapor pada Korlap

Semua yg hadir ikut, termasuk semua Direktur yg hadir

Laporan Korlap kepada Pimpinan Unilever

Kembali menuju tempat kerja masing-masing

Truck/transporter safety audit Special Safety reinforcement

Safety campaign: road & electrical safety Contractor safety commitment

29

LebaranWeek

CampaignCampaign

LebaranWeek 

Campaign

30

K3 Teknisi Listrik Program Sertifikasi Depnaker

31

Fire Training

32

First Aid Training

33

Defensive Riding & Defensive Driving

34

Health Activities

35

ULI FJB: WHAT COULD HAPPEN?

36

37

TOP 5 Hazards

1. Electrical

2 Fire/Explosion

C/D E

√ √

√ √2. Fire/Explosion

3. Slips/Trips/Falls

4. Squeezed in the crowd/Missing/lost

√ √

√ √

√ √5. Toxicated

√ √

√ √

C : ConstructionD : DismantlingE : Event

38

To Do In Every OBE

• Proper Legal Document/contractProper Legal Document/contract

• Identify the Hazard/Risks

C l h i k• Control the Risks

• Monitor/Evaluate the implementation

3939

SHE Risk Management  

AuditingProcess

Technology OperatingProcedures and Safe

Emergency Planning Practices

Management ofChange

Emergency Planningand Response

Management of ChangeChange

Process HazardsAnalysis

Incident Investigationand Reporting MANAGEMENT

LEADERSHIP & COMMITMENT y

Quality Assurance

Contractor Safetyand Performance

Training and

Prestart-Up SafetyReviews

Management of“Subtle” Change

gPerformance

40

Mechanical IntegritySubtle Change

B h dBut how to de-risk on an ongoing g gbasis?

M d si b si Made easier by using a checklist… e.g.

41

HOW?

We can now measure We can now measure non-compliance...

42

Refrigeration, Critical Pressure Equipment & Electrical Safety Self Assessment (formerly RBE Safety Self Assessment)

Version 2.1 2/4/2008

Self Assessments RCPE - Improvement Tools

43

Project Management: Tools for Success1 Before getting a new machine1. Before getting a new machine

- take Risk Assessments of similar machines and learn about the hazards you have to expect

l k f h f f- look for other sources of information like TPM maintenance standards, experience of maintenance people, line personnel.personnel.

2. Build a team with line personnel and technical staff and go to the supplier.

3 A t t h ith i l 3. Agree a start-up phase with special assistance of QA, SHE, technical department, development, planning and ensure regular meetings to collect g gall problems. Focus every day to the most relevant problems (Pareto!) and forget the rest until tomorrow.

44

4. Use a proper hand-over protocol to give the line to the site.

Basic OHS Tools

• Risk Assessment overviewRisk Assessment overview

• SIMAS 

• PHA

• HAZOP

• What‐if

4545

Progressive Motivation and Disciplinefor Safetyfor Safety

ion

DisciplinePositive Motivators Self-motivated

ee P

opul

ati

Safety as Value

Em

ploy

Safety as Value

46

Repeated Unsafe Behavior and Progressive Disciplineg p

Termination

ProbationaryPeriod

Termination

Written Warning

PeriodCorrective

Action Response

Induction & Re-Training

Counselling

VerbalWarning

bl i l f bili

Orientation TrainingRe-Training

47

Problem over Time or Level of Unacceptability

SAFETY REWARD & DISCIPLINARY COMMITTEE (SRDC)DISCIPLINARY COMMITTEE (SRDC)

1. Safety discipline is an integral part of employee work requirement

2 It i l if f t di i li t ll l2. It is equal or uniform safety discipline to all employees

3. The purpose of this system is not to fire people but avoid firing.

4. It is intended to nurture safe behavior thru positive recognation.4. It is intended to nurture safe behavior thru positive recognation.

5. The management through “Safety Reward & Disciplinary Committee (SRDC)” has the authorithy to apply the disciplinary ti ll i i ti f iti i f tactions as well as giving recognation for positive re‐inforcement

6. Disciplinary action is applicable for “Intentional Violation of  Established /Communicated Standard, Rules, Norm”. 3 substances which are– Intentional– Violation– Established or communicated standard/Rules/Norm

48

Established or communicated standard/Rules/Norm

Safety Award

Supply Chain VP giving safety helmet (DOT Standard) to an employee representative.

ULI Employee Safety Awards 2008 recipient

49

Summary

• Key Priority 1 : – Prevent Fatality, – Who : Contractors WorkersWho : Contractors Workers– Programme:

• SHE Plan, PTW + PTW Audit• Morning Briefing, g g• Site Operating Liscence (2 days course)

• Key Priority 2 :– Prevent Recordable Accident – Who : 3P inhouse + ULI frontline

• SBO• Education: Induction (Safety + Specific Location) by technical trainer incl transfereetrainer, incl transferee

• Audit

505050

Insight

1. Like any other business aspect, providing sufficient Leadership 

Commitment is very important In the beginning safety has toCommitment is very important. In the beginning, safety has to 

be start from the top.

2. In developing safety culture, having employee engagement has 

to be at first priority. Only when people buy in, the ball of 

safety start to rolling.

3 On safety continous education is as important as regular3. On safety, continous education is as important as regular 

reminder‐refreshment

51515151

T i K ihTerima Kasih

52