T-HSE Management System in EVRAZ Operations

Integrating Safety into Operational Efficiency

Modern production realities require a review of classical approaches to occupational safety. In the context of workforce optimization and the increasing complexity of technological processes, safety becomes an integral part of operational efficiency. During her presentation, Yana Reprintseva, Director of the Occupational Health and Industrial Safety Development Directorate at EVRAZ, analyzes in detail the transformation process of the HSE management system (T-HSE MS), where the key focus is on predictive analytics, behavioral work, and the involvement of production personnel.

The Problem of Unplanned Work and the Foundation of Safety

An analysis of occupational injuries shows that a significant proportion of severe incidents occur during the execution of planned tasks that are suddenly interrupted by abnormal situations. The speaker illustrates this with an example: when a crew is pulled away from the main process for the urgent unloading of arriving transport, the entire algorithm for safe work execution is disrupted.

To solve this problem, a systematic approach is proposed:

• Converting unplanned work into planned work. This allows the task to be provided with the necessary resources and risk assessment in advance, eliminating rush and chaos on the site.
• Implementing JSA (Job Safety Analysis). A one-page document is used for operations that were not previously covered by technological maps or work permits, providing a clear algorithm of actions taking into account emerging risks.
• Cascading planning. Task logging begins at the shop manager level (within a weekly horizon) so that the shift foreman does not face the need to integrate sudden tasks into an already formed daily plan.

Risk Heat Map: Digital Focus for the Manager

One of the most demanded transformation tools, which received a high response from production workers, was the digital "Heat Map". This is a dashboard (implemented on the basis of Power BI with the prospect of transitioning to a 3D model) that shows the accumulation of risks in specific areas in real time.

The tool solves the problem of distributing a manager's attention in large-scale production facilities. The map aggregates data from corporate systems and the "Risk Hunting" mobile application. It takes into account both static risks (constantly present at the site) and dynamic ones (arising in the moment). If a red indicator lights up in an area — for example, overdue measures to eliminate an identified hazard — the foreman or shop manager understands exactly where to invest their time today to prevent an incident. About 80% of the data for the map is collected automatically, minimizing manual input.

Role Specification and Performance Metrics

Calls for "safety leadership" often remain an abstraction for line managers. The presentation details the transition to specific requirements: 3-5 clear points of responsibility are defined for each production role (from shop manager to foreman).

Specific metrics and work standards have been developed for these points. This allows managers to understand exactly what actions are expected of them within the new HSE MS model, how to conduct line walkarounds, and what issues to raise at administrative cells.

What you will learn from this webinar:

• How do uncontrolled unplanned works affect the level of severe injuries and how to integrate them into the planning system?
• On what principle is the digital risk heat map built and what metrics cause it to "heat up"?
• How to automate the collection of hazard data using mobile applications and involve contractors in this process?
• How to translate abstract leadership requirements into 3-5 specific KPIs for shop managers and foremen?
• Why does analyzing employee behavior become more important than monitoring equipment condition when investigating incidents?