Enhancing Contractor Safety Management in a Steel Mill

A prominent steel manufacturing company faced challenges in managing the safety of contractors working within their facility.  This multi-site steel manufacturing organization that is a critical supplier to several industries that employs 2500 people and contracts another 2000 individuals.  With numerous contractors involved in various high-risk tasks and frequent incidents including serious injuries and fatalities, the company sought to improve its Occupational Health and Safety (OHS) contractor program to ensure a safer working environment for all personnel.

• Conduct an Assessment to identify Gaps in the current contractor management program.
• Develop a comprehensive contractor safety management program to mitigate risks associated with contractor activities.
• Enhance communication and coordination between contractors and the company contacts and employees.
• Ensure compliance with OHS regulations and industry best practices.

Our approach involved a systematic assessment and enhancement of the existing contractor safety management practices. The following steps were undertaken:

 

1. Initial Assessment and Gap Analysis

• Conducted a thorough review of the existing contractor safety management program.
• Reviewed contractor incidents and reports.
• Inspection and observation of contractor activities.
• Assessed the utilization of contractor third party for pre-qualification.
• Identified gaps and areas for improvement through site inspections, interviews, and document reviews.

Summary of Issues

• Incomplete Contractor Safety Management System documentation and implementation
• Not having a direct champion for the cause
• Lacking effective performance evaluation, reporting and trending metrics
• Siloed operations with limited communications
• Conducting hazard and risk assessment and control assurance too late in the contract process.
• Limited and varied scope of work definitions that included hazard identification, risk assessment and control identification
• Unstructured and non-standardized approach to contractor management.
• Approach

 

2. Development of Contractor Safety Management Plan

• Key Stakeholder involvement to create engagement and buyin, as well as to make the program specific to their needs and operations.
• Workflow and process defined
• Created a detailed contractor safety management plan, including support tools and documents a RACI chart, policies, procedures, and guidelines for contractor safety that included key stakeholders such as procurement, project managers, contractor contacts and the union.
• Created a clearer process map to determine and conduct resident contractor work, emergency contractor work and constructor contractor work.
• Developed specific safety requirements for contractors, including pre-qualification criteria, safety training, and performance monitoring.
• Updated contractor agreement inclusions
• Updated work package inclusions within their specific procurement and maintenance processes and supporting tech.
• Revised onboarding and orientation process and inclusions.
• Updated the Hazard and Risk Register for whole plant utilization, including that of contractors.

 

3. Implementation and Training

• Implemented the contractor safety management plan in phases, starting with high-risk areas.
• Conducted comprehensive safety orientation and training sessions for contractors, covering topics such as hazard recognition, emergency response, and safe work practices.

 

4. Enhanced Communication and Coordination

• Established regular safety meetings and communication channels between the Steel Mill stakeholders, employees and contractors.
• Implemented a system for reporting and addressing safety concerns and incidents promptly.

 

5. Monitoring and Continuous Improvement

• Established a monitoring system to track contractor safety performance and compliance with safety requirements.
• Conducted regular safety audits and reviews to ensure ongoing compliance and identify areas for further improvement.

• Improved Contractor Safety Performance
  • Achieved a significant reduction in contractor-related incidents and near-misses within the first year of implementation.
• Enhanced contractor adherence to safety protocols and procedures.
• Increased efficiency and effectiveness of position roles and processes around contractor utilization
• Decreased time downtime due to contractor issues
• Enhanced Safety Culture
• Reduced legal liability around utilization of contractors.
• Fostered a collaborative safety culture between the Steel Mill’s employees and contractors.
• Increased reporting of safety concerns and proactive hazard identification by contractors.
• Ensured compliance with relevant OHS regulations and industry standards.
• Received positive feedback from regulatory bodies during safety inspections and audits.

The OHS consulting intervention successfully addressed the critical safety issues related to contractor management. By implementing a structured contractor safety management program and fostering a culture of safety, the company significantly enhanced its operational safety and contractor well-being. This case study demonstrates the value of expert OHS consulting in transforming contractor safety practices and achieving sustainable improvements in high-risk environments.