Alumina Limited

Safety

As a non-operating partner in AWAC, Alumina Limited views workplace safety as a key performance indicator because:

  • It is a fundamental right for employees, contractors and visitors to be safe at work. 
  • It demonstrates the level of management control and expertise that Alcoa brings to operating the AWAC joint venture.
  • A safe work environment encourages work participation and attendance, which drives productivity and performance. 

Managing safety in AWAC’s complex mining and manufacturing environment requires strong systems as well as a focussed safety culture committed to continuous improvement.  As the operator Alcoa has invested substantial intellectual, financial and system resources over several decades to understand the key drivers behind safety behaviour with the sole aim of eliminating fatalities and serious injuries from AWAC’s operations. Alcoa's stated goal for a healthy workplace is to eliminate all health hazards that could potentially affect employees, contractors, and other individuals within their managed facilities which includes AWAC's global operations. If elimination is not feasible, Alcoa reduce the risk to the fullest extent possible.

Approach to Safety

Zero work-related injuries and illnesses remains the long-standing goal that is at the core of all training and initiatives developed by Alcoa as manager/operator of all AWAC facilities.

Alcoa have developed a strategy to continually build on safety practices and actively address safety risks.

Their approach to safety focuses on four main activities:

  • Identifying hazards and assessing the risks associated with products, services and operations
  • Developing and implementing both design and operational controls with built-in layers of protection to mitigate the impact of those risks;
  • Monitoring and maintaining our hazard recognition, risk assessment and operational control activities to ensure they are current and effective; and
  • Reacting to correct gaps in protective systems and continuously improving system stability.

Safety involves people and employee engagement is a crucial factor in creating and sustaining a safe work environment. At AWAC sites, efforts include safety suggestion systems, problem-solving teams, and pre-job briefings. Toolbox meetings, safety committees and individual accountability for specific aspects of safety. One initiative is the Stop for Safety coin campaign. It encourages and recognises employees who stop themselves or a colleague and seek help if they believe the situation is unsafe or they are unsure of the potential outcome. It is intended to reinforce employees that they have been delegated the authority to stop work when they perceive a potentially unsafe situation, regardless of the circumstances and will be supported by management.

In assessing progress towards a goals, the two main safety metrics include: 

  • Lost Workday (LWD) Incident Rates: which represent temporary or permanently disabling incidents that impact the long-term health and welfare of employees and contractors.
  • Total Recordable Incident (TRI) Rates: the more frequent incidents in critical areas, such as ergonomics, noise, and hand/finger injuries that result in lost time or restricted work activity, as well as those that require medical treatment.

Results and goals 2015

Sadly, the goal of zero fatalities was not achieved in 2015 following the unfortunate death of a maintenance contractor working at AWAC's Kwinana alumina refinery in Australia. The contractor entered a digester tank and fell approximately 20 metres (66 feet). A thorough investigation was conducted into this tragic incident and the findings were communicated to all of AWAC's locations.

To raise awareness of the need to adhere to technical, process, leadership or organisational defences, Alcoa have instilled a safety system and culture that enables AWAC’s employees to:

  • Recognise hazards and error-likely situations
  • Implement tested and safe methods for performing job tasks
  • Improve the effectiveness of pre-task safety briefings
  • Stop work until an identified hazard can be eliminated or controlled
  • Provide layers of protection from recognised hazards
  • Apply lessons learned to predict areas of current and future vulnerability
  • Monitor for potential deviations from safe and proven methods, and
  • Address contractor and contracted services safely.

Fatalities by Gender

Employees/contractors

 MaleFemale
2010 1/0 0
2011 0 0
2012 0 0
2013 0 0
2014 0/1 0
2015 0/1 0

Lost Workday Rate

Employees and supervised contractors

 GlobalAustraliaEuropeNorth AmericaSouth America
2010 0.22 0.54 0 0.46 0.12
2011 >0.19 0.19 0 0.28 0.11
2012 0.17 0.58 0.11 0 0.02
2013 0.20 0.50 0 0.25 0.05
2014 0.17 0.42 0 0.50 0.06
2015 0.16 0.2 0 0.23 0.09

Lost workday rate represents the number of injuries and illnesses resulting in one or more days away from work per 100 full-time workers

Lost Workday incidents by Gender

Employees and supervised contractors

 MaleFemaleTotal

2010

32 2 34

2011

14 2 16

2012

29 0 29

2013

26 1 27

2014

22 1 23

2015

11 0 11

Days Away, Restricted and Transfer Rate

Employees and supervised contractors

 GlobalAustraliaEuropeNorth AmericaSouth America

2010

1.18 1.69 0 3.82 0.43

2011

1.07 1.73 0.45 3.95 0.39

2012

0.71 1.54 0.22 1.55 0.14

2013

0.56 1.19 0 1.11 0.08

2014

0.51 0.86 0.12 1.01 0.09

2015

0.39 0.42 0.12 0.92 0.09

Days away, restricted and transfer rate includes lost workday cases plus cases that involve days of restricted duty and job transfer per 100 full-time workers.

Days Away, Restricted and Transfer Incidents by Gender

Employees and supervised contractors

 MaleFemaleTotal

2010

114 11 125

2011

1212 12 133

2012

87 4 91

2013

66 4 67

2014

46 1 47

2015

23 0 23

Total Recordable Incident Rate

Employees and supervised contractors

 AustraliaEuropeNorth AmericaSouth America

2010

3.62 0 5.35 0.78

2011

3.43 0.45 5.08 0.45

2012

2.81 0.34 2.95 0.44

2013

2.39 0.11 3.19 0.23

2014

2.06 0.46 4.36 0.40

2015

1.0 0.36 4.72 0.09

Total recordable incident rate represents the number of injuries and illnesses resulting in days away from work, job transfer or restriction, medical treatement or other recordables per 100 full-time workers.

 Total Recordable Incidents by Gender

 MaleFemaleTotal

2010

227 17 244

2011

223 13 236

2012

169 6 175

2013

141 5 146

2014

127 6 133

2015

81 2 83

 

AWAC’s total recordable injury rates has gradually decreased in Australian operations from 3.62 in 2010 to 1.0 in 2015. 

Zero work-related injuries and illnesses remains the long-standing goal that is at the core of all training and initiatives developed by Alcoa as manager/operator of all AWAC facilities.

Alcoa has developed an approach to safety that involves four main activities:

  • Identifying hazards and assessing the risks associated with our products, services, and operations – business units proactively identify and eliminate potential hazards in the work place going beyond regulatory compliance and looking for ways to reduce injuries;
  • Developing and implementing operational controls with built-in layers of protection to mitigate effectively the impact of those risks – procedurews developed to to cover boeth internal activities such as hazardous energy and fall protection, and externalactivities including contractor and product safety;
  • Monitoring and maintaining hazard recognition, risk assessment, and operational control activities to ensure they are current and effective – tracking key performance indicators for each location and periodically testing and calibrating those performance indicators against safety objectives and action plans to determine their effectiveness in measuring and monitoring overall safety performance and
  • Reacting to correct gaps in protective systems and continuously improve system stability.
  • Annually, the AWAC operations as aligned to an Alcoa business unit, are challenged to analyse its injury experience and develop and implement a problem-solving and improvement plan that addresses its risk profile as it relates to our injury performance. While individual business-unit risks vary, the key corporate drivers include: employees new to the job (less than 18 months); hand and finger injuries; significant ergonomic risk; exposure to slips, trips, and falls; and seasonal or non-routine task exposures.

Alumina Limited’s results

While Alumina Limited has a relatively small operational footprint, we focus on our safety performance through training. There were no recordable injuries for the year or Lost Work Days as a result of incidents.

*LWD and TRI Rates are based on 200,000 work hours