Huntsman Petrochemicals improved safety for 300 employees and made cost savings by introducing a behavioural safety programme. Employees benefited from fewer accidents and the company reduced operating costs.
Despite an excellent safety record, Huntsman Petrochemicals was concerned that some ‘near misses’ could have led to significant injury. The operations manager thought that improved safety behaviours at all levels of the company could lead to improved reliability and less likelihood of a major incident.
Huntsman implemented BSAFE – a proprietary behavioural-based safety system
‘As I carry out everyday tasks, I am constantly (probably subconsciously) reminding myself of things I must and must not do! I find myself noticing things (and doing something about it!) that I may have ignored before.’
S Gell, Operating Technician
The average, annual running cost of BSAFE is around £238,000. This includes training costs, time and salary of BSAFE observers and coordinators and the IT software. A large proportion of the costs would have been incurred anyway via a different department. The operations manager’s conservative estimate of savings on utility losses is £250,000 a year. BSAFE helped control steam leaks, saving around 5te/hour of steam. The savings in utilities, combined with the £multi thousand saving in insurance premiums more than offset the annual cost of BSAFE.
The senior environmental, health and safety manager at the site raised the profile of behavioural safety. He supported the BSAFE process as part of the company’s business manufacturing technique.
Key safety representatives from unions (TGWU and Amicus) were actively involved by recruiting the coordinator and observers. The representatives are very supportive of BSAFE.
‘The introduction of BSAFE has brought about a fundamental shift in attitude towards Safety, Health and Environment. It has for the first time allowed every individual in the business to personally take responsibility for their own safety and for the safety of others’.
Paul Booth, European, Vice President of Manufacturing and Technology.