Development of a Safety Culture at Tugnuisky Open Pit JSC

The mining industry is traditionally associated with a high level of occupational injuries, where standard control measures are often insufficient to prevent incidents. During the webinar, Alexey Leonov, Industrial Safety Director at Tugnuisky Open Pit JSC, discusses a comprehensive approach to developing a safety culture based on an in-depth analysis of critical risks and the implementation of multi-level barriers.

From Injury Analysis to Risk Management

A retrospective analysis of accidents over 14 years became the foundation for transforming the enterprise's safety system. Using real incidents as examples, the speaker demonstrates how missing barriers — in process organization, regulatory documentation, or equipment operation — lead to injuries. To prevent such situations, the top 8 critical risks were identified, and simple, practical management methods were developed that do not complicate the work of line personnel.

Digital Tools and Employee Engagement

Special attention in the presentation is given to the digitalization of routine processes and the creation of a transparent feedback system. The implementation of a QR code system made it possible to solve several practical tasks at once:

• Recording hazardous conditions: employees can promptly report violations at their workplaces and receive financial rewards for doing so. This stimulates a conscious attitude towards safety and helps identify hidden threats.
• PPE provision control: the request processing service directly connects employees with the supply department. If the required size is not in stock, scanning the code instantly sends a request to the responsible persons, eliminating the loss of information in paper logs.

Technological Solutions for a Safe Environment

The specifics of open-pit mining and the round-the-clock operation of equipment require the use of reliable technical protection means. The presentation details the solutions implemented at the open pit:

• Visualization of danger zones: the use of directional light systems (Red Danger Zone) clearly marks the boundaries around special equipment, which completely eliminated collisions of heavy trucks with fuel tankers.
• Driver condition monitoring: monitoring systems prevent operators from falling asleep during monotonous work, reducing the risk of driving into a ditch or colliding.
• Individual voltage indicators: after analyzing the causes of electrical injuries, stationary and wearable devices (attached to a helmet or arm) were introduced, which automatically warn personnel about approaching a voltage source.

What you will learn from this webinar:

• How to build a barrier system for critical risks so that it is actually applied at the executor level?
• How to overcome the language barrier when training foreign workers in HSE rules?
• What technical solutions help eliminate blind spots and collisions of mining equipment?
• How to organize the effective evacuation of a victim from large-scale equipment over 6 meters high?
• What are the benefits of cross-audits and how do they help combat "blurred vision" among line managers?