HSE vs. Production. Three Levels of Struggle

HSE vs. Production: Finding the Balance

Implementing a safety culture at an industrial enterprise often faces resistance at all levels: from workers who perceive requirements as a hindrance, to managers focused solely on production indicators. In this webinar, Alexey Kuzin, Head of the HSE and Production Control Department at JSC MC BMZ, breaks down practical tools for overcoming this barrier and building an effective Occupational Health and Safety Management System (OHSMS).

Three Levels of Control and Engagement

The speaker details a three-level safety management model, where each level has its specific tools and areas of responsibility.

Level 1: Production Area (Foreman)

At the basic level, the key role is assigned to the line manager. Main tools:

• Safety Cross: A visual indicator (green/yellow/red) filled out daily by the foreman. Important insight: a completely green cross is a signal for an inspection, as minor non-conformities always exist. Recording a violation in the cross eliminates the need for duplication in prescriptions, motivating foremen to independently work with problems.
• HSE Boards: Fully maintained by the foreman. They reflect risks, PPE, ergonomics, and the action plan for improving conditions.
• Risk Assessment: Transferred from HSE specialists to working groups led by the foreman. Monthly risk control is carried out using checklists by the operators themselves.

Level 2: Department (Shop Manager)

At the shop level, the focus shifts to systematic work and personnel engagement:

• HSE Day: A monthly thematic event (from Vision Zero to safety at home). It includes non-standard formats, such as quests to find violations and investigate simulated injuries, as well as quizzes.
• Performance Indicators (KPIs): Metrics have been introduced that do not directly affect bonuses but publicly evaluate the department's performance: the effectiveness of eliminating violations (no repetitions), timeliness of response, maintaining boards, and the quality of the HSE Day.

Level 3: Plant (Directorate)

The highest level requires "safety marketing" to demonstrate the real picture to management:

• Directorate Meetings: Regular review of HSE issues with the participation of the General Director. Data from all levels is analyzed: from minor non-conformities to the implementation of the zero injury concept.
• Integration with the Production System: HSE is viewed through the prism of lean production, where any injury or incident is treated as a loss.

Working with Micro-injuries and Effectiveness

The presentation shows how the enterprise works with micro-injuries. A Quick Response Control (QRC) tool is used to determine root causes (Ishikawa diagram, "5 Whys"). Each micro-injury is investigated by a line manager's commission, recorded in 1C, and monitored by the respective director. This approach allowed the enterprise to achieve zero minor and severe injuries for the year.

What you will learn from this webinar:

• How to make the "Safety Cross" work and why the absence of violations is a bad sign?
• How to motivate line managers to independently identify and eliminate risks?
• What non-standard formats (quests, quizzes) are effective for holding an HSE Day?
• How to integrate HSE into a lean production system?
• How to properly structure work with micro-injuries to prevent serious incidents?