graduation thesis

Dissertation Graduation Bachelor Degree – IBMS in HAN UNIVERSITY

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EEuurrooppee ((BBPPEE))??

Sub-questions

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HHooww mmuucchh mmoonneeyy ddooeess BBPPEE OOssss BB..VV wwaassttee ffoorr iinnssuurraannccee ccoossttss dduuee ttoo tthhee

ddaammaaggee ooff aacccciiddeenntt ooccccuurrrriinngg ffrroomm llaasstt 1100 yyeeaarrss uunnttiill nnooww??

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IInnffoorrmmaattiioonn CCoonnttaacctt

MMeennttoorr:: HHaannss VVaann DDeenn HHeeuuiijj

CCoommppaannyy CCooaacchh:: HHaann FFlluuiitt

SSttuuddeenntt:: JJoohhnn HHuuyynnhh

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AAdddd:: PPaarraalllleellwweegg 11,, NNLL--55334499 AADD OOssss,, NNLL

DDaattee:: 0011--0044--22000099


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Acknowledgements: Nowadays, accident and incident is the big problem with operational manufacture lines, especially it is more responsibilities than with multinational company such as Ball Packaging Europe.

In BPE, Health and Safety is top number one among of top-five list such as: efficiency, quality, spoiled and cost. Appreciating with the important level of H&S, we always keep going on to make surveillance and analysis to find out the proper solutions for control of hazard. This internship in BPE, I am starting project risk management and working upon to ISO STANDARD 18001:2007(an international H&S standard written by UK organization) that be worked parallel to ISO 14001 environments, ISO 9000 quality. Working with this project, I also have training in risk management BPE; meeting with top management every morning to keep on eye the process of performance, interview with employees in the line to receive their feedbacks then making analysis, give the corrective action program and evaluation of results of performance . To complete project successfully, I really want to give my special thanks to:

All employees, they are very friendly to corporate with me in line

My company’s coach , Hans fluit coordinator in H&S who is very sincerely and kindly to help me all during I am doing project

My colleges, Team leaders who is very friendly and corporate to share their skill and experience for me.

Mentor, Hans van Denheuij who helped me kindly in completing my graduation project successfully.


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Executive Summarize: Ball Packaging Europe (BPE) is one of the leading beverage can producers in Europe. A wholly-owned subsidiary of Ball Corporation, an international producer of high quality packaging, Ball Packaging Europe reported turnover of EUR 1.3 billion in 2008 with 2,900 employees. Twelve production plants situated in close proximity to clients in Germany, France, the United Kingdom, the Netherlands (located in Oss city), Poland and Serbia ensure that the company has extensive presence both in the traditional core markets of Western Europe and also in the significant growth regions of eastern and southern Europe. Ensuring operational manufacture line is going well from different local areas all over the world, annual year BPE faced with many problems about H&S of all employees and hardly protecting them far away from incident, accident in the line. BPE must adhere well to the regulations, procedures and constitutions about H&S for employees in local governments. And take care that is lowest incident, accident in line during year working. According to the accident statistics report of H&S Department in BPE, annually in average there are about 58 to 110 accidents and more than 213 incidents in Ball Packaging Europe (BPE). These damages leaded to BPE had been spent a huge of insurance cost to set up again the mechanical systems and medical treatment of employees. In averagely these figures are about 3,896 million of dollars annual year, separately in Oss plant that amount is about more than 0,52 M Dollars yearly ,(More detail about insurance costs please see in the chapter 2/2.2Total accidents, incidents during last 10 yrs and chapter 5/achieved results and attachment ). This time, doing internship in Risk management of H&S department in BPE Oss B.V, I realized this hot problem and chose it is my graduation report. The proposal research question is made: “How can we attain the target of near zero accident/incidents, Minimum insurance costs and good environmental manufacture performance and Maximum PR imaginable values for Ball Packaging Europe (BPE)? Upon to the full meaning of above proposal research question, it can be understood simply as “how can we control incident, accident decline to near zero in workplace?” To answer this hard question fully, clearly and strategically, I have to spend four weeks to think how to work with this. I took a step to read a lot of books of other authors in risk management. I have the reference from different ideas of my


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colleges, take a short term training course, and use data in SAP network (system analysis program) to investigate accidents, incidents from all operational manufacture lines worldwide in Ball Corp. I always keep my eyes to look how people working in the line, how machinery system working, interview with workers from the line and attend the meeting from 9:00 in the morning daily to keep the progress of the performance and report it to planning management team . In conclusion, how can accident, incident be solved?

Basically there are 5 steps in risk management to find out the solution for accident, incident measurement.

11.. HHaazzaarrdd iiddeennttiiffiiccaattiioonn

22.. RRiisskk aasssseessssmmeenntt

RRIISSKK MMAANNAAGGEEMMEENNTT SSTTEEPPSS

33.. DDeetteerrmmiinnee ccoorrrreeccttiivvee aaccttiioonnss

44.. EExxeeccuuttiioonn ooff AAccttiioonnss

55.. RRiisskk eevvaalluuaattiioonn


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Above each step, I have to use Matrix model to calculate level of hazard and immediately to give the proper solution. We can say this is the most important and flexible method to measure risk among of other ways.

CATEGORY CLASSIFICATION MATRIX RISK RATING

BPE Risk

Evaluation Matrix

Likelihood of occurrence

1 2 3 4 5

Severity

1 1 2 3 4 5

2 2 4 6 8 10

3 3 6 9 12 15

4 4 8 12 16 20

5 5 10 15 20 25

1 – 8. LOW

9 – 15. MEDIUM

16 – 25. HIGH

And here is the following solution that can be applicable in measurement of hazard:

BBS (based behavior safety) observation Regulations, procedures that force to be applicable in ISO

Standard 18001:2007 Risk management JSA (job safety analysis) Training for skills and awareness of employees PPE using (personnel protection equipment) SAP Network to record accidents, incidents and using for

reference in BPE worldwide In the end, I already make up a developing corrective acting programs that should be kept developing more in the future. Moreover, I also have my special advice in H&S that can be used for innovation and application prospectively in BPE. (Please see my conclusion for clear detail)


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Table of Content Preface…………….. …………………….………………………………………2 Executive Summarize…………….……………………………………………..3 Chapter 1: Introduction ……………………………………….………….…..7

1.1 Imaginable PR values of BPE. ……………………….…………….7 1.2 Problems occurred due to unsafely work ……………….………...8

1.3 Mission of Health and Safety …………………………….………....8 1.4 Objectives ………………………….................................................9 Chapter 2: Literature Review Literature Review ………………………...10 2.1 Introduction …………………………………………………….…....10 2.2 History of accidents, incident during last 10 yrs………….……....11 2.3 Reasons and Results of Accidents / Incidents……………….…..12 2.4 Power of Government’s intervention ………………………..….....13 Chapter 3: Methodology ………………………………………….……......14 3.1 Introduction ……………………..……………………………….…..14 3.2 Analysis Causes & Effects of Incidents/Accidents……………....15 3.3 Solutions ………………………………………………………….…17

3.3.1 ISO STANDARD 18001:2007…………………….…...17 3.3.2 BBS Observation …………………………………….....19 3.3.3 Risk Management………………………………….…...21 3.3.4 Training ………………………………….…………… ...24 3.3.5 PPE……………………………………….……………....27

Chapter 4: Recommendation……………………………………………......28 Chapter 5: Achieved Results & Conclusion ……………….……….……...30 Reference ……………………………………………………….……………….37 Appendix ……………………………………………………….……………...…38


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Chapter 1: Introduction Ball Corporation is committed to the health, safety and welfare of its employees. We strive to make all the rules of life in the countries where we operate. Our efforts are going beyond compliance with regulations alone. The health and safety of each member of Ball Corporation have priority in all our work. The management is responsible and accountable for the security work to prevent disease and injury at work in our businesses is conducted in accordance with our objectives in the field of social security. For achieving the objectives of occupational Ball Corporation is the commitment of management and the active participation of all employees is necessary. All employees are expected to make their own health and safety observance, as well as the health and safety of others whom their acts or omissions may affect. The continuous improvement of occupational safety is achieved, documented, maintained and evaluated. For Ball Corporation's sustainable focus on care for its employees and the community it is necessary that each of us actively contributes to improving the health and safety. Our long term goal is "zero" accidents.

1.1 Imaginable PR values of Ball Packaging Europe (BPE) due To good risk management: Ball Corporation’s sustainability focus to care for employees and communities requires that each of them be proactive in enhancing employee health and safety. Zero accidents are the long-term goal. Building an urgent network H&S from European Union which is always in ready condition to help and solve problem of H&S of employees and to Sponsoring good quality of products, protecting healthy of customers , achieved loyal product using of customer in long term .

Systematical development of a consistent, concise company image with a public- and internal perception – Corporate identity with its Health and safety to sponsor that BPE is not only premium services, good products but also building up successfully its brand name `s reputation to customers in long term and achieved the credits with external stakeholders .

Please see the attachment: chapter 1/ 1.1/page 7, page 8 /procedure Award of Excellence


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1.2 Problems occurred due to unsafe behavior of employees? More than 85% of all accidents are caused by unsafe behavior. For BBS (based behavior safety), the accidents of the past three years inventoried. Many of the accidents were the employees are not aware of the risks they ran. It claimed an unsafe action. Unconsciously and with all good intentions: => Year 2006: 89.3% (unawareness of workers in H&S) => Year 2007: 85.0% => Year 2008: 81.3%

Can these accidents be prevented?

Yes, if one is aware of the risks and take into account many accidents can be avoided. Attentions to the work, to follow the proper procedures, use the right tools and protective equipment and a tidy, concise work are the basis for a safe working environment. BBS is one of the important management tools of risk management for a culture change to achieve. This makes security a part of our routine that we shared with each other and display a pro-active environment in which accidents to minimum.

Safety is aware of acceptable risks Conduct of staff plays a major role when it comes to security. For the right to develop is also timed. With the aim that the number of accidents each year between 10-25% declines may indicate that within a few years we want to and where we are today.

1.3 Mission of Health and Safety

Creating a safe environment for our employees, visitors and motivating our employees. Health and Safety of each individual is of paramount importance in the conduct of our business.

Management is responsible and held accountable for ensuring the means and methods for managing the risks inherent in our operations to prevent occupational injuries and disease

We continuously distinguish ourselves by exceeding the required local Health and Safety expectations and permanently adding value to the health and wellbeing of our employees.

Achieving the credits in H&S of the customer value in long term.


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1.4 Objectives

Zero Accident approach supported by OHSAS (Occupational Health and Safety Assessment Series ) 18001 implementation

Commit ourselves as a responsible member of society to act to ensure a safe working environment and the development of our employees work.

Ensuring that health and safety practices are adopted in our operations to prevent illness and occupational injuries in line with our social sustainability goals.

Making sure that everyone be proactive in health and safety

To achieve the strategic targets, close co-operation between all manufacturing functions is imperative:

Objectives

Methods Monthly conference call

meeting

Controls Key performance

indicators

Accident/incident statics alerts

Inputs H&S policy

Risk assessment

Legal requirements

Outputs Measurable objectives

for all functions

Human resource Director & Manager of

H&S

Plant management team

Materials Directives and

Relevant sate regulations


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Chapter 2: Literature Review 2.1 Introduction: During working, I have used some books and authors which very famous that help me very much in this report to conference and posting the audits such as Heninrich`s Domino theory, Peter d.wickens, kiyoshi suzaki , W. Edwards Deming , regulations and knowledges of ISO 18001 …..Etc but the most of important author who I usually have conference is Henrinrich with Domino `s theory. Nowadays this theory step by step updates and develops with many scopes that are very effective and convenient for risk management. (Please keep your eyes on my attachment `s address: chapter 2/2.1 intro/

page 12/Summary the Heinrich’s)


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2.2 History of total accidents, incidents during last 10 yrs Recently:

According to the statistics of data record system H&S in BPE, averagely there

are more than 85% of accidents/incidents that occurred annually due to unsafely

behavior in working and here is the following more detail statistic numbers:

75 to 100 fatal accidents

Hospitalization and /or permanent injury about 200,000 small accidents

which is 80,000 injury

Up to 3000 reporting and surveillance about probability of accident occur:

Among of ± 7,500,000 workforce, 1 in the ± 35 persons annually an accident

That wasted a lot of money maybe up to hundreds thousands to million Dollars

and other damages for BPE.

(For more detail please keep your eyes on my attachment `s address:

chapter 2/2.2/ page 14/Safety is aware of acceptable risks

chapter 2/2.2/ page 15/Costs & benefits /A. cost accident last 10 yrs

chapter 2/2.2/ page 16/Costs and benefits /B. costs

chapter 2/2.2/ page 17/Costs and benefits /C. saving


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2.3 Reasons and Results of Accidents / Incidents

2.3.1 Reasons of Accident/incident

Almost equally rapidly , not proactive in task

No PPE Any deviation from procedures

Not the right resources

Order and cleanliness inadequate

Hurry, do quickly with the result

Insufficient attention to the work They don’t think accident will come to them, it comes to other people

2.3.2 Results of Accident/incident

According to the Knowledge’s data base from Health and safety of Ball Packaging Europe Corporation about monthly statistics for all injury types, body parts and work areas that occurs accidents and incidents in the line. Here is the following statistics numbers report about results of accident occurred which I already described very detailed by graph and it is explained clearly the level of each accident, incident that I attached with address following:

Attachment `s address: chapter 2/2.3.2/ page 19 page 20, page 21/Results of accident/incident


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2.4 Power of Government’s Intervention Most of the operational manufacture lines in EU especially in Netherland together have Labour inspection organization which is established by government and working legally paralleled within those lines to fulfil their responsibilities and creating, maintaining H&S working conditions for employers and employees. In Netherland, it is called by the name Arbeidsinpectie .The Dutch Safety and Health Act (Arbowet) contains a code of conduct for safety & health policy and the Working Hours Act (Arbeidstijdenwet) forms a statutory framework for working hours. The Labor Inspectorate ensures compliance with the legislation. A number of financial measures have been implemented to reward good conduct and to penalize bad practices. Besides that, the Ministry encourages executives and workers to cooperate and take an active role. The Ministry also encourages all parties involved to actively increase expertise. When there is accident that damage highly to the people and make them lost their works to stay in hospital more than 24 hours or even laceration , wound to the body of employees then immediately that organization force the line to stop running and they send the experts to investigate accident . Or when there are some incidents are very dangerous that can be damage to H&S of employees, environment then they also force stopping the line upon to the obligations are defined in particular by the Civil Code and the Arbowet , Article 7:658 . This article was introduced in April 1, 1997. It replaced the older Article 7A: 1638x BW until the incidents is solved. (More details about rules and regulations please have your reading to website: http://www.arbeidsinspectie.nl/index.cfm and my Attachment: Chapter 2/2.4/page 23, 24, 25/statutory duties in relation to Healthy and Safety)

http://www.arbeidsinspectie.nl/index.cfm


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Chapter 3: Methodology

3.1 Introduction Working with this project, I have used many methods, guidelines and training from BPE event making interview directly face by face with my colleges who are very corporately and kindly to help me to full fill my knowledge. Moreover , my company `s coach who is very proactive to help me all guideline and send me to go to many departments in BPE to have training and reference the knowledge and sharing experience , skills in Risk management . In BPE, I always working actively in the performance and treated such as a staff employee by Ball even I usually sent to ball school in quarterly of year to have training with many ways to make sure that I sufficient skills in Risk management to working the performance efficiently . Team group working is the effective method that also is the habit in BPE. In the early morning, we always have meeting to report the problem and receive the ideas to find out the proper solutions.


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3.2 Analysis the causes and effects of incidents/accidents

If accidents/incidents had occurred or we had been in poor environment then what did happen in the past about causes and effects?

Causes

Effects

PPrroobblleemmss

AAppppeeaarr wwhheenn

AAcccciiddeenntt //

iinncciiddeenntt ooccccuurr In the line

Wrong doing , failed in efficiency Expenditures for recovery a new program in safety working system, poor housekeeping in the line or bad transport cans due to increasing spoilages. Not adhere to the procedures well, wrong doing, working a lone, working distraction, all due to accident occur. Insufficient labour force to operate system due to incomplete the performance, incidents in transports occur, high spoilages.

Failed management

Costs increase

Labour force decrease Failed deliver cans on time


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PPrroobblleemmss

ooccccuurr dduuee ttoo

bbaadd

EEnnvviirroonnmmeenntt In the

operational manufacture

line

Cans are not enough standard, bad scrapper, cans in bad hygiene due to poor housekeeping. Costs increase, high customer complaints, bad quality, poor environment due to decreasing stockholder values. Poor housekeeping, high spoilage cans, bad transport input/output, high ink substances, changing labels, cans in bad hygiene, technical incidents in mechanical system. Poor environment, many accident which directly affected to the healthy and safety of employees and local people.

Customer complaints due to the loose customers for long term

Stockholder values decrease

Bad quality due to loose customers , weakness in competition

Responsibility in law

due to stop running the line


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3.3 Solutions

3.3.1 ISO Standard 18001:2007

Introduction: OHSAS 18001 is a Health and Safety management system with British standards classification. OHSAS stands for ‘Occupational Health & Safety Assessment System’, it is the benchmark that all Ball Packaging plants in Europe are committed to achieving. There are now a total of 192 standard risk assessments under 94 headings with over 600 PM&R RA’s being written as well as our COSHH RA’s being reviewed! OHSAS 18001 Front page procedures which Provides the legal compliant framework for Health and Safety management . Standard Risk Assessments Certification to OHSAS 18001 demonstrates a company's commitment to a safer working environment and for the protection of employees against injury at work Certification should assist in organisations saving money and maintaining a good reputation. Certification also provides a platform for attracting lower insurance Premiums, developed to be compatible with the ISO 9001 (Quality) and ISO 14001 (Environmental) management systems standards. Ensuring legal and regulatory compliance . The company should establish and maintains a management system that conforms to all of the requirements of OHSAS 18001. This should also assist the organization in the meeting every morning which is appliance legal or other OH&S regulations. The level of detail and complexity of the OH&S management system, the extent of documentation and the resources devoted to it are dependent on the size of an organization and the nature of its activities. So that up to the issues , regulations, policies , terms in ISO STANDARD 18001:2007 , all of workers , management team from all departments in the plant must adhere well seriously , proactive in their H&S and working connection together systematically ,pay attention more to performance , ensure that running machines is safety and healthy environment around the line.


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Planning for Hazard identification

Policy: put into practice

Audit: assess and review on a regular basis the effectiveness of the policy in the regular meeting

Implementation and operation: consult increase employee’s awareness of the OH&S, Economic, and Financial requirements on the Company and report any significant changes which may occur.

Feedback from measuring performance: improve the flow of information and feedback as a means of discussion with, and feedback from employees.

Here is the summarizing of Solution ISO STANDARD 18001:2007 1. Duty people who got authority to make accident Monitor that the scheduled actions have been completed investigation 2. Root causes of accidents

Material

Environment

Personnel

Management 3. Steps to investigate 4. How to collect the facts of accident, incident

Injured workers

Record of accidents on KDB (knowledge’s data base ) of BPE`s network

Physical evidence

Eyewitness accounts

Interview with people to investigate For more detail about my solution ISO STANDARD 18001:2007 please keep you’re into my Attachment: chapter 3/3.3.1/ISO Standard 18001:2007/page31 to page 46


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3.3.2 BBS Observation Ball Packaging Europe Oss (Oss BPE) is a production company. All employees are focused on making products that are safety often lose sight. Often this happens unconsciously and with all good intentions. More than 80% of accidents in BPE Oss can be back in the unsafe behavior of workers. These accidents are preventable. Through Risk management should increase the awareness on safety and safe behavior is a matter of course. This will ultimately reduce the number of accidents. 1. Identifies the behavior accidents may occur BBS is a system based on safe behavior. Through observations of work makes safety negotiable and we collect data on behavior. With BBS, we incidents / injuries on the workplace safety to be a part of our daily routine .Unlike traditional security, which focuses on accident reduction, BBS is a systematic approach. 2. Encourages this behavior by motivational feedback 3. Meet safely to prevent accidents and unsafe behavior to predict and prevent. Traditional vs. Security Most current efforts in the field of security will take place after an accident has occurred. At that time, actions to prevent such an accident in the future . This is re-active security. That's not the best approach. BBS is an approach to pro-active way to show risky behavior and increase awareness so that this risky behavior change and the likelihood of accidents decrease. In other words, BBS focuses on accident prevention.


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Benefits of BBS

Goes beyond regulatory requirements

Identifies accidents before they occur

Provides pro-active measurement data

Targets unsafe acts/behaviors

Allows for positive safety dialogue

BBS Observation Program

Observe → Act → Reinforce → Talk → Report

Personal Protective Equipment Good Housekeeping Use Of Tools & Body Position Use Of Equipment Access To Machinery Reactions/Positions of People PPE Housekeeping Procedures


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3.3.3 Risk management

Risk assessment is a process of identifying hazards and determining their associated risks. In practice, a risk assessment in the workplace is an examination of what could cause harm to people in that particular environment. The outcome is an action plan which helps employers to focus attention on reducing risks where it is needed and to prioritize any action to safeguard against harm occurring to people. An improvement cycle

Risk assessment in practice is a continual cycle of improvement. The workplace and what goes on there continually changes, and so too should the risk assessment. The diagram below shows that change, review and action to reduce risks are all key stages in the risk assessment process. This continual cycle helps to ensure that health and safety standards are kept high.

Finally, there are five generally recognized steps to completing a risk assessment. These five steps can be used as a guide to help you think about the areas which you're required - by law - to cover in a risk assessment.


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Working the five steps will involve some careful preparation, the process of actually assessing the risks and then taking action to reduce risks. In order to properly complete the steps, risk assessors need to have a good knowledge of the business, the workforce and activities going on.

So basically, there are five steps to measure accident, incident:

Step 1 Identify the hazards Spot hazards by:

walking around the workplace asking employees what they think calling the Workplace H&S Connect Advice line or visiting website of expert checking manufacturers’ instructions; Checking accidents, incidents on SAP Network to have update accident

from other lines on the world for reference. Keep in mind long-term health hazards

Step 2 Decide who could be harmed and how

Identify groups of people. Remember: I. Some workers have particular needs II. People who may not be in the workplace all the time

III. Members of the public If we share our workplace think about how our work affects others present Always say hoe the hazard could cause harm

Step 3 Evaluate the risks and decide on precautions

What are we already doing? List what is already in place to reduce the likelihood of harm or make any

harm less serious What further action is necessary?

We need to make sure that we have reduced risks so far as is reasonably practicable’. An easy way of doing this is to compare what you are already doing with good practice. If there is a difference, list what needs to be done.

Step 4 Record your findings and implement them

How will we put the assessment into action? Remember to priorities. Deal with those hazards that are high-risk and have serious consequences first.


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Step 5 Review the assessment and update if necessary

Review our assessment to make sure we are still improving, or at least not sliding back.

If there is a significant change in the workplace, remember to check our risk assessment and where necessary, amend it.

Please keep your eye to see the explanation of each step of risk management in my attachment: Chapter 3/3.3.3 risk management/ page 51/ 56

Supportive Toolkit Management

Risk Management Toolkit provides a wealth of information and many tools for management. Quickly accessible, this extensive Toolkit offers practical assistance for many risk management needs.

Please see my attachment: Chapter 3/3.3.3 risk management/Supportive toolkit management/ page 58

And: Chapter 3/3.3.3 risk management/information Information and tools/page 59, 60, 61


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3.3.4 Training And Development Programs

Introduction: In this chapter, I had references in many famous books such as “principles of HMR” Dessler, Kiyoshi Suzuki with “The new manufacture challenge”. Guest,D.R.Pecci & P.Rosenthal with management training and development and career success in K.Bradley “people and performance” . Scholtes,P.R(1987) An elaboration on Deming`s teaching on performance appraisal ….etc.. It is very important to build up foundation of acknowledge and it is also definitions, principles that already has been used from long time until now. As we can know training is the best important and a major part of the responsibility to develop employees within BPE according to the need and potential and to ensure appropriate succession planning as well as to serve the short and long term staffing requirements of the company. Personnel’s H&S development of each employee is a key responsibility of each manager within BPE. We can say most of accidents, incidents that ever happened in the line due to awareness and ignorance of employees. So the important thing in the mean time is finding out the effective training programs for employees, help them Awareness of H&S themselves and capacities in working performance effective.

People focus as one critical success factor

We want to meet current and future business needs through the ongoing development of our knowledgably people. Motivation, communication and satisfaction as well as health & safety are essential to maintaining an engaged and challenged workforce. All training needs should be agreed between employee and manager in the one to one interview, during the process of annual review and reported the local HR department. Employees interested in registering, training on my ball portal (Ball Packaging Europe’s net work system) and interoffice mail or fax to local HR Department as well as to the HR Office personnel. There are some important main points which are really needed to focus on during training:

Language of instruction


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Due to the fact that BPE employees are unified through the English language all course offered as well as the provided material; will be in English Therefore, fluently in English is extremely important and essential for successful completion of the training. Should fluency in English not be of the required standard, please contact your local HR department to organize a similar training in the respective mother tongue of the employee.

Attendance /Punctuality To stay reasonable, cancellations should be made at least one week in advance

Dress code The dress code during the training courses is casual. Suggesting employees bring a jacket or sweater to class, Due to the large amount of electronic equipment, temperature of our training rooms tends to be cool.

Individual and team skills

Intercultural awareness training

Intercultural skill training

Seven habits of highly effective people

Management and Leadership skills

BPE leadership training

Advanced leadership

Technical skills

PEP – audience oriented presentation methods

Employee can school

Project management Training Details

Intercultural awareness training

Intercultural skill training

The seven Habits of highly effective people

BPE leadership training

Advanced leadership training

Audience orientated presentation methods

Presentations and group discussion Please see my attachment: Chapter 3/3.3.4Training And Development Programs/page 62 to 68


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Role of supervisors

As a supervisor, you have an important role to play in ensuring the health and safety of people, in a number of ways:

o ensuring safe work practices are implemented; o explaining their importance; o setting a good example yourself; o helping to promote a safety culture and; o Rewarding safe behavior.

People may lack experience but it is still important to actively seek their views and encourage their participation in safety matters. There should be arrangements in place for young worker health and safety based on a risk assessment. Measures need to be monitored to check they work as expected and may need revision if there are any changes. So, it should be reported any problems or changes, and encourage people to report any problems and concerns too. Exposes them to radiation;

o Involves extreme heat, noise or vibration; o Involves risks that they are unlikely to recognize or avoid because

of their lack of experience or training or their insufficient attention to safety.

Fact sheet ‘Protection for people in the workplace’ provides more details of task and hours restrictions according to age, and special exceptions for vocational training. If there are any doubt about the work of people, raise it with the employer. Check national requirements.


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3.3.5 Personnel Protective Equipment (PPE) As to the regulations and standards of European Union Health and safety personnel protective equipment (PPE) is designed to protect employees from serious workplace injuries or illness resulting from contact with chemical, radiogical, physical , electrical , mechanical and other workplace hazards . It is depending to style of business of manufactures line of its self business to design the right PPE using for employees `s protection in work programs. Especially, all PPE using in the line which is recognized and issued by the standards of H&S of European Union Upon to the regulations and standards in H&S of EU Labor of Department, Ball Packaging Europe must supply safety protection equipments for employees in the line sufficiently and it is basically including equipments as following as:

1 CEN/TC 79 Respiratory protective devices

2 CEN/TC/85 Eye protective equipment

3 CEN/TC/158 Head protection

4 CEN/TC/159 Hearing protectors

5 CEN/TC/160 Protection against falls from height working, safety belts

6 CEN/TC/161 Foot and leg protectors

7 CEN/TC/162 Safety Vis-jackets

(CEN/TC 79 to 162: regulations and standards about safety equipment of EU standards) Let see more in my attachment: Chapter 3/3.3.5/page 36, 37 Work program


28

Chapter 4: Recommendation Developing corrective action programs in the future

To gain with the above objectives about H&S successfully in protection our employees and customers out of incidents/accidents and especially protection the brand name Ball Packaging Europe competitively of the leadership in packaging industry in the worldwide To sponsor that it is on safety running business in long term, we should keep going to develop more H&S management programs in each local manufacture line from BPE network over the world. In the present, immediately we should develop projects about H&S and using it such as manual risk control basically in the operating manufacture line:

International ISO STADARD 18001:2007 BBS observations Instructions , Guidelines, checklists PPE JSA (job safety analysis in risk management , it is attached together

with this report about the “ Job Safety Analysis sheet form “)

DEVELOPING SOLUTIONS PROCESS FOR ACCIDENT OCCURENCE

FA: First Aid ….NM: Near Miss……NLT: None lost Time ….LT: Lost Time

Please see explanation more in attachment “BPE statistics report “


29

`̀

Deployment

BPE

procedures

through plant

SOP`S in own

language/

Format

Comply with

OHSAS

requirement of

incident

recordkeeping.

The SAP

incident

management

system is

designed for

this purpose

Challenge

plants to set

BPE best

practices

Make observers

accountable for

regular observing

Plant management evolved in BBS

program by review

checklist by regular

base and assuring

checklist with

Measure

improvement safe

behavior. This

shows the success of

actions based on

determined

structural unsafe

behavior

Check to

ensure

RA is

updated

by means

of review

Measure

how safety

knowledge

is managed

by means of

training and

instruction

Measure

how good

PPE rules

are

followed

up in

practice

Compliance

with BPE

OHSAS 18001

system which is

based on BPE

best practice

benchmark

Plan

management

is critical

regarding

PPE and

execute

review

actual

identified

risks are

evaluated

against the

PPE practice

Observation should

include verbal

feedback to

observed

colleague(s)

.outcome of this

plan be noted as

workers comment.

This is important

information to get

more understanding

about the actual

practices

All working

areas should

……. And

assessed.

Have

regular

safety

refreshme

nt training

to

maintain

awareness

All working

area’s should

covered by

RA in order to

have all

related

Hazards

identified and

assessed

Full

appliance

of PPE

Measure use

PPE through

BBS

observation

card

Measure

use PPE

through

BBS

observation

card

Make RA

comparable

within BPE.

This enables

exchange of

this

knowledge.

Working

methods etc.

Ball

corporate

sustain

Ability

report in

Compliance

with GRI


30

Chapter 5: Achieved Results & Conclusion

Introduction

If we check back the data numbers about accident, incident and H&S of labor force in

BPE last ten year, especially pointed years recently year 2006 to 2009 then we can

appreciate that accident and incident has been declined sharply.

In the meantime, we are in good progress, achieving success in many aspects, especially

in Healthy and Safety, setting up a safety operational manufacturing environment,

protection H&S of employees and customers in producing and using products.

That means we can save millions of Dollar insurance costs for Ball Corp, good top-

minder task in protecting H&S of employees; make sure that sponsoring enough Labor

force for Ball Corp about Skill and certification and over-matching with a higher

expectation standards of Department of Labor legally .

We are absolutely successful in building up best products, best premium services and best

safety using products can especially we are best efficiency in managing and measuring

with accident. That is also the important factor helped Ball to become a leadership in

Packaging industry and gained many excellence Awards.

Year 2009 Ball Packaging Europe has been chosen top-100 Corps on the world in H&S

and lowest accident in operational manufacture lines.

(Please have a look in my attachment)


31

Primary Key Result

1. Accident, incident decreased sharply

A> Performance measure achieved :

Protection H & S of employees

Results of Accident occured from 2006 - 2009

35

22

15

3

3540

25

7

0

10

20

30

40

50

Year

Accid

ent

LT

NLT

LT 35 22 15 3

NLT 35 40 25 7

2006 2007 2008 2009

As we can see , it is clear to appreciate that accident , incident already decreased

pointedly from 35 LT (lost time) and 35 NLT (none lost time) year 2006 to 3 LT and 7

NLT quarterly 2009 in BPE .

Please see explanation detail in attachment file: statistics Report 2006,2007,2008,2009.


32

Decreasing insurance cost

(Unit of insurance cost; USDx10.000)

Results of Lost workdays & Insurance Costs from 2006-2009

779

456

240

50

303

17792 58

0

100

200

300

400

500

600

700

800

900

2006 2007 2008 2009

Year

Lost w

ork

days &

Insura

nce C

osts

Lost WorkDays

Insurance Cost

And above graph show that happy result for BPE to save a lot of money when from year

2006 Lost workdays was 779 correlative with 3 M USD insurance cost that made a huge

damage for Ball Corp and other bad things .

But if we keep seeing from years 2007, 2008 the data to be declined clearly and finally it

was temporally stop with 50 lost workdays and 0.58 M USD insurance cost in quarterly

2009.

It is success to gain that target due to we are in good using proper solutions in Risk

management control, working to procedures, innovation in performance skills, especially

we are in solidarity working and be proactive in each of our individual H&S.

So finally, it is all about insurance cost year 2006-2009 in BPE. Separately in BPE Oss

B.V, these figures had been declined happily from 0, 93 M Dollars in 2006 to 0, 61 M

Dollars in 2009 dramatically. Please have a look my attachment “statistics report” to see

more detail about insurance cost yearly, total accidents…etc…

Let see explanation detail in attachment file: statistics Report 2006,2007,2008,2009.

B> Goal:

Trying best to decline minimum accident, incident as we can


33

2. Training for performance skills & certification in employment

A> Performance measure achieved:

Getting awareness of H&S of employees

As I already mentioned in chapter 3 and 4, it is about more than 80% the root of

causation of accident, incident that happened in the line due to people not awareness of

H&S. They never think that accident can be happen to anyone including themselves.

So in this part , it is time to train for people and guide them clear about characteristics of

level of risk in them everyday , help them skills to protect their life, concentration on

their working and remind them always be owner in their H&S.

Percentage of trainees who full fill the skills, obtain

employment and increase labor force for company as well

as bring the benefits for each of individual participants

Training achived in H&S

181 192 200

42 5783

23.20% 29.69% 41.50%0

100

200

300

year

Hu

mar

eso

urc

e

Employment

Certification

% of certification

Achieved

Employment 181 192 200

Certification 42 57 83

% of

certification

Achieved

23.20% 29.69% 41.50%

2006 2007 2008

From 2006-2008, labor force has been increased pointedly, especially top management in

BPE recognized that the ignorance of know ledges of employees is the main factor lead

to fail in management because Awareness and skills , know ledges is the most important

thing to protect H&S of employees and running line safety . So we tried our best to

motivate and made chance for employees to working and training to get the license

legally.


34

B> Goal:

Keep going on to exceed requirements of regulations and standards of

Labor of department

3. Efficiency

A> Performance measure achieved:

Risk management achieved during working performance

Efficiency = Actual/Target (Unit= %)

The percentage of Efficiency in H&S that obtained measurement

75% 80% 83%

60%

72% 75%80.0%90.0% 90.4%

0%

20%

40%

60%

80%

100%

Target

Actual

Efficiency

Target 75% 80% 83%

Actual 60% 72% 75%

Efficiency 80.0% 90.0% 90.4%

2006 2007 2008

Target: maximum output (working capacity of planning management team and

The adherence of employees about procedures in BPE)

Actual: total real output that obtained in H&S during working

As we can see on graph, it is absolutely change data during 2006 to 2008 (should be

mentioned 2009 but it is in progress to update the whole year).

Generally, the process is going well, it is developing in good tendency recently from

2006 to 2008 with 80.0% to 90.4% dramatically. But it is also hard to keep this statue in

the future if we are not motivated ourselves and awareness of everyone together with

solidarity spirit of all employees in BPE in performance.

C> Goal: Doing the thing right


35

Conclusion

It is very pleased when we take a look to see again all performance results achieved from

BPE in H&S of employees in the line recently last ten years.

Upon to the efforts and challenges of all workers and management team in BPE, we not

only met with standards and requirements in sponsoring H&S of employees but also

exceeded the great majority of customer’s standards, local Government’s regulations in

the line as well.

Moreover, it is not just temporally stop here but it will be kept going on to do the

research and find out more effective proper solutions which is not only protecting Ball’s

H&S of employees but also saving insurant costs for company, especially building up

BPE brand name successfully in customer’s eyes and keep the statue top-leadership in

packaging industry and top-100 Corps in Honor about lowest accident in operational

manufacture line.

Here are the following core strategic challenges to be kept in progress and more

development in the future for the accident, incident control:

Proper management solution tool for controlling accident, incident in the line

Training for performance skills & certification in employment Awareness of H&S

Efficiency (Leading and Controlling the performance in H&S efficiently )

Best Can in quality and safety H&S for customers using

Increasing facilities , safety guards , equipments…etc… more safety and effective

using in performance

Strictly adhere well to the procedures, always proactive in owner of H&S of each

individual of employees

Working upon to the ISO STANDARD 18001:2007 , 14001 , 9000

Keep developing BBS observation

System analysis program Network (SAP NETWEAVER PORTAL)


36

Special planning advice for development in the future

Workers Workers Workers

When Procedures about H&S be issued by top-man and H&S Department

Then immediately all other departments must be obeyed and work in order as following:

1) Acting: Top man and H&S making analysis risk then planning proper solution

and do it for trial and back up again to make sure before sending it to production

department. Finally, production department and team leaders forwarding to

workers from the line to obey and working strictly.

2) Discipline: in case if employees don’t obey procedures strictly then they will be

remarked with bad report into their profile.

Best practice is developed from PCDA model of W. Edwards Deming in H&S and

quality in operational manufacture line.

PCDA Model

Please have reference in website http://www.mindtools.com

BEST PRACTISE

Top management

H&S Department

Production

Man .Team Man .Team Man .Team


37

Reference

Some Regulations, European Agency for Safety and Health at Work http://osha.europa.eu/en/legislation/directives/ http://www.iosh.co.uk/index.cfm?go=technical.details&scid=13 http://osha.europa.eu/en/good_practice/index_ralink?SearchableText=&keywords%3Alist=risk_assessment&submit=Search

Standards (EUROPEAN COMMITTEE FOR STANDARDISATION)

http://www.cenorm.be/ Occupational Safety and Health Sector: http://www.cen.eu/cenorm/sectors/sectors/healthandsafety/occupational+health+and+safety/index.asp

European harmonized standards under the New Approach directives:

http://www.newapproach.org/ http://eur-lex.europa.eu Kjeen.U.Boe, K.and Hagen, H.L (1997) Economic effects of implementation

internal control of healthy and safety, environment: A retrospective case study of

an aluminum plant.

Regulations, information guideline of ISO Standard 18001, 14001, 9000 in

knowledge data base in Ball Packaging Europe net work (internal staff employee

using only).

Heninrich`s Domino theory. Peter d.wickens with the ascendant organization.

The new manufacturing challenge of kiyoshi suzaki. W. Edwards Deming.

What`s new in motivation of Guest,D.(1984) with personnel management.

Guest,D.R.Pecci & P.Rosenthal with management training and development and

career success in K.Bradley “people and performance” .

Scholtes,P.R(1987) An elaboration on Deming`s teaching on performance

appraisal . Trade Union Congress (1994) with Human resource management

http://osha.europa.eu/en/legislation/directives/

http://www.iosh.co.uk/index.cfm?go=technical.details&scid=13

http://osha.europa.eu/en/good_practice/index_ralink?SearchableText=&keywords%3Alist=risk_assessment&submit=Search

http://osha.europa.eu/en/good_practice/index_ralink?SearchableText=&keywords%3Alist=risk_assessment&submit=Search

http://www.cenorm.be/

http://www.cen.eu/cenorm/sectors/sectors/healthandsafety/occupational+health+and+safety/index.asp

http://www.cen.eu/cenorm/sectors/sectors/healthandsafety/occupational+health+and+safety/index.asp

http://www.newapproach.org/


38

Appendix

Attachment’s Files: Chapter 1/ 1.1/page 7, page 8 /procedure Award of Excellence

Chapter 2/2.1 intro/ page 12/Summary the Heinrich’s

Chapter 2/2.2/ page 14/Safety is aware of acceptable risks

Chapter 2/2.2/ page 15/Costs & benefits /A. cost accident last 10 yrs

Chapter 2/2.2/ page 16/Costs and benefits /B. costs

Chapter 2/2.2/ page 17/Costs and benefits /C. saving

Chapter 2/2.3.2/ page 19 page 20, page 21/Results of accident/incident

Chapter 2/2.4/page 23, 24, 25/statutory duties in relation to H & S

Chapter 3/3.3.1/ISO Standard 18001:2007/page31 to page 46

Chapter 3/3.3.3 risk management/ page 51 to page 56

Chapter 3/3.3.3 risk management/Supportive toolkit management/ page 58

Chapter 3/3.3.5/page 36, 37 Work program

Chapter 3/3.3.3 risk management/ page 51/ 56

Chapter 3/3.3.3 risk management/Information and tools/page 59, 60, 61

Chapter 3/3.3.4Training And Development Programs/page 62 to 68

President’s Safety Award. BPE Safety Statistics Report 2007, 2008, 2009.

Top 100 Best Corp Citizens 2009.

Research Report assessment form (be assessed by Mentor)

Company Coach Evaluation Form 2 (used after 6 month)

Internship Hour Declaration Form (it is filled by student signed by coach)

Final interview assessment form (to register result of final interview and

published in the course of the year).


39

graduation thesis

Documents