Heineken
TPM Safety Pillar Newsletter Global News
New developments, training and training materials in HeiQ
The Safety Master Pillar team have been working to review our TPM approach on Safety. A number of new
developments including new revision of the Safety Pillar, improvement teams approach on operational risk
reduction, accident and incident investigation and the newly customised Safety PKE training are among the
recent developments, as well a thorough review and significant upgrade of all support materials; previously the
EFESO Toolbox, which are all now located in and maintained in the Heineken Knowledge Management
System - HeiQ. In this newsletter we take the opportunity to summarise the improvements for you to
communicate with your Safety Pillar teams.
New Safety Pillar Route Safety Compass
Earlier this year we published a revised Safety Pillar based on a
“housekeeping” exercise to embed previous develops, updated PKE
training and support materials including, safety pyramid concept,
conformance to (HeiQ) rules, standards and procedures and legal
requirements, safety aspects in 5S activities, safety induction for visitors
and contractors, roll out plan for „Operation Risk Reduction‟ for whole site
including warehousing, emphasis on visual management, machine lock
out review, behavioural aspects and reward and recognition on safety.
The next step was to review the logic of the Pillar following the safety compass principles and bench our
approach against our peers. This exercise allowed us to further embed both reactive; systematic
investigation and proactive; hazard identification and risk management approaches, people focus and
establishing the “safety system”. Therefore we redefined and consolidated the Pillar steps with main
differences as detailed below. The new Pillar and support materials will be issued in Jan 2012.
Step 1 – Identify safety priorities & restore, achieve basic conditions
Reviewed logic of sub steps “to perform gap analysis” in order to define priorities and targets, additional
guidance on link to HeiQuest. Specified review of working permit system, LOTO and PPE procedures as a
“basic condition” and basic safety awareness training performed for all levels as a “basic condition”.
Step 2 – Systematically investigate accidents and incidents
Focus is on the “systematic analysis” of accident, incidents via establishing a Process Owner, fault tree for
analysis (ongoing development; similar to BDA approach), select and train safety experts, champions in all
departments who are also available to support accident, incident analysis.
Step 3 – Hazard identification and risk management
Step “name change” to reinforce proactive approach.
Ensure safety approval e.g. of CILT‟s, OPL‟s, SOP‟s and
maintenance standards to ensure „safe working practices‟.
Review work permit and LOTO procedures defined in
Step 1 or previously. (note, development of standard
risk assessment method is ongoing).
Step 4 – Focus on people via competences,
culture and behaviours
Step name change to reinforce Step 5 – Use the safety system
correct approach of competences, established to further improve
culture, behaviours and defining safety
critical behaviours Establish this step as “further improving safety” via
for safety. the ongoing use of the safety system established.
Define reward, Previously there were 2 steps; “implement the
recognition safety system” and “further improve safety” .
and sanction systems. This was neither efficient, nor logical. Therefore a number of new sub
steps have been defined including; introduce management of change
system. Define safety aspects and communication in DCS, emergency
planning and response, define all safety aspects and controls in
contractor management. Imbed basic safety training for all employees
and advanced training for H&S experts. Horizontal expansion and
New Safety Pillar Route for 2012 systematic updating of risk assessment and reduction of residual risk.
December 2011
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Global News
Reviewing the Safety Improvement Team Routes
As described earlier we have put additional emphasis within the Pillar on hazard identification and risk
management and subsequently therefore have also revised the improvement teams approach. Previously there
existed 3 improvement routes; Accident Reduction, Accident Risk Reduction and LOTO improvement. These
improvement routes have also have been consolidated and “Heinekenised” into “Operational Risk Reduction
(ORR) and an updated “Accident, Incident, Near Misses Reduction Route” according to the logic of the new
Pillar.
New Operational Risk Reduction (ORR) Improvement Route
This route replaces accident risk reduction and LOTO improvement focusing on prevention and risk
management. Based on the “high level” risk assessment performed typically at site level based on legal
requirements, deployments of data from the safety pyramid, an area / machine roll out plan is defined. The ORR
team approach then performs a detailed risk assessment and thorough analysis of all tasks and activities to
improve physical aspects, workplace standards, behaviours and procedures. Ultimately reviewing all elements
related to man, machine, materials, method, environment, and management. We are currently collecting good
practices from our Breweries, including warehousing for verification and would like to be distributed as a
references and re-application were applicable. Please send us your examples.
ORR Roll out
Planning
New Accident, Incident, Near Misses Reduction Improvement Route
Scope of new route is expanded to accidents, incidents and ultimately near misses. Additional emphasis is
placed on ensuring a stronger link to vertical deployments of data coming from safety pyramid and the
assignment letter to identify the accidents, incidents and near misses common trends defining mode(s) to attack.
When applying countermeasures
reviewing all aspects of man, method,
machine, material, management and
environment to address all lines of
defence is an addition.
Hierarchy of Control Reference
December 2011
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Support and PKE Training Materials Global News
New Safety PKE Training
Until recently the main source and origin of knowledge
for the Safety Pillar was the Efeso toolbox. This material The Safety PKE training is now a fully customised
was designed to be generic and mainly for instruction PKE according to all the new materials and “latest
purposes. Therefore the detail level, and customisation thinking”. In addition the training is managed and
to the Heineken world was limited. As introduced earlier performed together with SHE Specialist; Dietmar
there has been significant upgrade to the PKE training Laske, GSC Supply Chain Services and Tomasz
and support materials. Please visit the Heineken TPM Kus, GSC TPM.
Toolbox in the HeiQ where all materials are now The first “new look” Safety PKE was held in
stored and will be regularly updated. Zoeterwoude in October 2011, with Sopron;
Hungary and Austria in November 2011. Apart
from new materials, a number of new exercises
were also performed in the including safety
tagging, safety analysis, safety observations and
new team routes. These were good opportunities
for practicing “safety tools” and were appreciated
by the participants.
Thanks to Dietmar and Tomasz for the good
preparation and management of the training.
The Training and support contents are as follows –
Contents
Safety Pillar Overview
• Concept of Safety
• Safety Pillar Introduction
Safety Pillar Steps
• Safety Pillar Step 1
• Safety Pillar Step 2
• Safety Pillar Step 3 Safety PKE training in Zoeterwoude
• Safety Pillar Step 4
• Safety Pillar Step 5 Managing the transition to the New Pillar
Safety Pillar Improvement Team Routes Early in 2012 there will be a web cast available
• Operational Risk Reduction (ORR) to explain the changes and improvements to
• Accident , Incident and Near Miss Reduction the Safety Pillar, Team Improvement Routes,
training and support and transition to the new
Safety Pillar Support Documents
Pillar. Addition PKE trainings and workshops
• Introduction of accident analysis will also be available, your regional office and
• Procedure for Accident Analysis (5Why) Heineken University will provide more
• Safety pyramid, deployments and target setting information on this. Finally there will be no
• TPM Safety Pillar Step 1.4 R,S&P changes in the Safety Pillar checklists in 2012,
this will be introduced from 2013 onwards.
• TPM Safety Pillar Introduction of Near Misses
• Pillars support to Safety The Safety Master Pillar Team
Safety Pillar & Team Audits We recently reviewed the composition of the
• Pillar Audit Checklist Safety Master Pillar Team and I take this
• Step Audit check list opportunity to thank the new team for their
Templates contributions and work so far. The team now
consists of Pjotr Van Oeveren; Leader, Dietmar
Safety PKE, Workshops Laske, Tomasz Kus, Franco Zurru, Ad Belder,
• Training Course Agenda Frank Rohmer, Pamela Brown, Hugo de Blank,
Safety Good Practices / Examples Lance Hiscoe, Radoslaw Borowski and Peter
Ebner; central and regional Champions.
December 2011 christopher.kerr@heineken.com
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