Achievements in the Proactive Development of Safety Culture. How to Maintain the Standard?

From a Reactive Approach to a Proactive Safety Culture

The development of a safety culture is not a one-time project, but a systemic transformation requiring the involvement of all company levels. The presentation details the experience of Metalloinvest Group, which began its transition from a reactive to a proactive level in 2021. The speakers demonstrate how auditing and engaging consulting services became the starting point for creating a five-year program aimed at zero injuries.

Risk Identification Tools: From Walkarounds to IT System Integration

The speaker analyzes the evolution of hazard identification tools. The traditional "risk hunting" on-site was supplemented by "risk hunting in operations" — detailed tracking of complex multi-stage processes from preparation to equipment launch. This made it possible to identify hidden threats that are unnoticeable during a routine inspection.

To improve the efficiency of maintenance services, integration with the SAP Mobile EAM system was implemented. Now, identified risks automatically enter the maintenance work plans, and according to regulations, they are obliged to respond to them, which eliminates the ignoring of problems.

Personnel Involvement and Process Digitalization

An important element of the system was the introduction of a corporate portal and a mobile application for recording risks and non-conformities. To motivate employees, a reward system (points store) was created, but the focus is not on the quantity, but on the quality of the identified threats. As a result, workers began to record critical risks associated with equipment and cranes, which helped prevent real accidents.

In addition, the speaker emphasizes the importance of proper communication with workers based on the principle of "listen, look, and ask." This triggers a process of conscious attitude towards safety, instead of formally listening to instructions.

How to Measure and Maintain the Safety Standard

To control and maintain the achieved results, a manager evaluation system was developed. It includes four blocks: training, safety radius assessment (quality of line walkarounds and communication with people), and standard work execution on the portal. High scores in this system are integrated with HR processes and affect the receipt of bonuses.

An assessment of tool adoption is also conducted: specialists from different plants cross-check each other, identifying weak points and forming recommendations for improvement.

Practical Case: How to Justify Safety Investments

The presentation provides a real example of how a systematic approach helps convey the need for urgent investments to top management. During a line walkaround, critical destruction of the central conveyor's metal structures was identified. Instead of abstract requests for funding, specialists developed compensatory measures, calculated costs, and presented a justified plan to the committee under the CEO. This allowed them to quickly obtain financing without stopping production and formed the basis of a new work regulation through a risk passport.

What you will learn from this webinar:

• How to modify traditional "risk hunting" to identify hidden threats in work processes?
• How does integration with IT systems (e.g., SAP) help control the elimination of violations?
• How to build a motivation system so that workers record critical risks rather than chasing points?
• By what criteria should managers' involvement in safety culture be assessed, and how to link this to their KPIs?
• How to properly justify the need for urgent investments in critical equipment repair to top management?