HPI Training Panel Workshop – Hanford Experience

September 12-13, 2006

Waste Treatment Plant ProjectBechtel National Inc.

2

HPI Training Common Themes

• Executive DOE/contractor management buy in is essential• Joint contractor/DOE training is beneficial• Facility specific and general HPI training is well received by all

audiences• Management participation enhances training effectiveness• Need a continuing communication process to reinforce concepts

and celebrate successes• Interactive training (videos/exercises/role play) is more effective

than lecture• Different classes for different audiences is needed• Field workers have less need for theory and more need for practical

application

HPI Training Panel Workshop – Hanford Experience

CH2M HILL Hanford Group, Inc.September 12-13, 2006

4

CH2M HILL’s HPI training strategy is to incorporate event CH2M HILL’s HPI training strategy is to incorporate event prevention tools and precepts throughout its processes to prevention tools and precepts throughout its processes to

enhance ISMS implementationenhance ISMS implementation

HPI Enhancing ISMS Implementation

Event Prevention

5

Process for Integrating HPI Training Into ISMS

• Apply industry (INPO) best practices• Initial HPI training• Perform HPI Gap Analysis• Identify HPI training gaps• Integrate training actions into ISMS improvement plan• Develop HPI Training Needs Analysis• Train the trainer to facility specific processes• Conduct HPI training • Regularly assess effectiveness of HPI training with

HPI Steering Committee

6

HPI (Event Prevention) Training

• Focus on facility specific applications allows for immediate application in field• Work packages• Procedures• Engineering Design• Work planning• Walkdowns• Pre-Job Briefings • Work practices • Post-Job Briefings• Lessons Learned• Management / Self Assessment• Event Investigations

7

HPI Training Courses

• Practitioner Class (24 hours) • Work Management Process • Training and Procedures • Trainers• Complete (about 50 trained)

• Fundamentals Class (8 hours)• Field Managers• Subject Matter Experts • In progress (about 75 trained)

• General Worker Orientation (3 hours)• Supplemented with ongoing training• In progress (about 400 trained)

• Introduction to Event Prevention (2 hours)• All field personnel • Complete (about 900 trained)

8

HPI Tool Provided to Trained CH2M HILL Employees

9

Lessons Learned

• INPO (benchmarked) process was effective• Executive management training and buy-in is essential• Management kickoff sets tone for change• GAP Analysis and training needs analysis effective in determining training

content and durations• Facility specific, practical applications allows for immediate application • Facility trainers adds credibility and sustainability • Emphasis on event prevention and ISMS integration

▪ Minimize use of “HPI” terminology or new initiative (flavor of day)• Entertainment examples enhance training experience• Use of badge card with HPI tools beneficial• Procedure checklist and other tools useful for implementation• Cost to develop: $30K (364 person hours)• Cost to provide: $30K (374 person hours)• Student cost: $350K (5100 person hours)• Training took about 6 months to develop and present

10

CH2M HILL Improvement Cycle

CH2M Prime

Contractor

1999

*DART 3.6

2000 2001 2002 2003 2004 2005 2006

Problem Evaluation Report

(PER) System

ESTARS

Vapor Issues

Safe Work Environmen

t (SWE) Culture

AssessmentMandator

y Respirator Usage in

Farms

ISMS Expectations

4/15/05

Human Performance Improvement

Training

Integration of SWE,

ISMS & HPI

Follow-up SWE

Survey

Acc

iden

t In

jury

Rat

e

PIP Addressin

g OA Vapor Issues

244-CR Vault Event

7/22/04

Mission Alignment Process (MAP)

SWE Mentoring

IROF ISMS

PIP

DART 1.0

DART 0.1

IROF

A-Prefix Farms –

Mask Cessation

WFO VPP Star Status

IROFDisciplinary Process Revised

*DART – Days Away and Restricted TimeNot to scale – For illustration only

11

ISM Best Practice WorkshopAurora, CO

Sept 12-13, 2006

HPI Training Panel Workshop – Hanford

Experience

12

HPI Training

• HPI Training Plan▪ Enhance ISM & VPP successes▪ Understand how events occur working “forward,

not backward”▪ Shift the paradigm (“a new language”)

• Audience▪ Focus on management, supervision, and key

Bargaining Unit personnel▪ Develop Work Force understanding of HPI▪ Establish HPI mentors to implement the

process at the Project level

13

HPI Training

• Training Format

▪ Eight Hour HPI Fundamental Course• Safety Leadership 2006 – The Basics

– Why HPI events occur– Error likely situations– Error precursors– Flawed defenses

• Over 600 managers and supervisors attended

• Over 100 Bargaining Unit Peer Leaders and Support Professionals

14

HPI Training

• Training Format

▪ Four Day HPI Practitioners Course• For those individuals “who will have

responsibility for training, implementing or managing a Human Performance Process”

– Three Continuing Education Units following course and essay final exam

• Application of HPI tools, techniques and problem solving

– Focus on error precursor identification, investigation, barriers and case studies

• 65 FH graduates– 20 scheduled for classes through CY 2006

15

HPI Training

16

HPI TrainingField Pilot Implementation

• Pilot Implementation Plan for the Solid Waste Storage and Disposal (SWSD) Facility▪ Training▪ Precursor Issues identification▪ Observation Program

• Peer monitoring in the field▪ Work Planning▪ Pre Job Briefings ▪ Critique Process

• Peer interviews• Three day extension

17

HPI TrainingField Pilot Implementation

18

HPI TrainingField Pilot Implementation

• Pilot Implementation Training▪ SWSD:

• Ten Exempt and Bargaining Unit personnel attended the Site HPI Pilot training

– Included Facility Director, OS&H Engineer and EZAC chairpersons

• Developed HPI project-level Steering Committee– Led / mentored by trained personnel – Initiated Work Force briefing and seminar sessions

▪ Waste Stabilization and Disposition Project• Twenty personnel trained in preparation for Pilot

expansion– Included Vice President, several Directors, each

Facility Manager and each EZAC Chair

19

HPI TrainingField Pilot Implementation

• Worker briefings and seminars

▪ Safety Day activities at least once each month

▪ Safety meetings and EZACs▪ Discussed identification of error precursors

through photos and videos▪ Use of HPI language in

meetings, daily activities

and Project documents

20

HPI TrainingField Pilot Training

• Planning▪ Project-level training Gap Analysis▪ Identified training applicable to early stage of HPI

development• Focus Areas

▪ HPI concept fundamentals• Safety meetings and briefings

– Concepts and application• Interactive review of current topics

(Occurrences and recent airline accident in Tennessee), for

– Error precursors– Latent weaknesses

▪ Employee involvement training• Skits• Training mock-ups Safety Meeting HPI Skit

“Fly with SWSD Air”

21

HPI TrainingField Pilot Training (Cont’d)

• Field Work Supervisor Competency▪ Work planning, pre-job/post-job, feedback▪ Skills inventory and improvement planning

• Development of Working Leads▪ Leadership training

• Latent Organizational Weaknesses Addressed▪ Conflict in the workplace (risk

acceptance/personality styles)▪ Emotional I.Q. training▪ Development of conflict prevention skills

22

HPI TrainingField Pilot Implementation

• Successes of Pilot

▪ Workplace Observer Program improved by focusing on error likely situations rather than physical inspections

▪ Workers self-identify barriers and errors that stall work or create error-traps

▪ Additional Senior Management visibility and interaction with workers

▪ Pre-job briefings focus on critical steps and defenses

▪ Event investigations use HPI techniques with Peer involvement

▪ Early conflict resolution process developed

23

Future of HPI Training

FH views HPI and the next natural progression of VPP & ISM in Improving the “People Side of Safety”

• Expand on the pilot successes ▪ Establish company level steering committee▪ Expand the Pilot to the WSD Project▪ Continue HPI Practitioner Training▪ Expand to all FH Projects

• Target training courses for specific application▪ Engineers, planners, critique leaders, procedure writers▪ Incorporate HPI into site training on

• HAZWOPER• Practical - HPI Training Laboratories

24

River CorridorClosure Project

Safety • People • Results

U.S. Department of EnergyRichland Operations Office

HPI Training Panel Workshop – Hanford

Experience

Phillip KeuhlenDirector, Safety, Health & Quality

September 12, 2006

25

WCH Approach to Human Performance Improvement

• Conceptual Framework: Toolset That Supports Integrated Safety Management

• Principle Focus is on Error Prevention ▪ Greater cost benefit ratio than Error Detection or

Corrective Action▪ Field deployable tools▪ Intuitive understanding

26

Tailored HPI Training

• Certificate Class (U of Idaho, 32 hours)*• First Line Supervisor Workshop (Embedded, 8

hours)*• Manager Fundamentals (8 Hours)• Work Team Orientation (3 Hours)• Continuing Communication Campaign

* Highlighted further on following slides

27

Certificate Class

• Formal 32 hour course taught by BushCo with University of Idaho at Idaho Falls certificate

• Target objective is development of Subject Matter Experts (~24 graduates)▪ Management & Staff Sponsors▪ Event Investigators▪ Functional SMEs

• Safety• Human Resources• Training

28

First Line Supervisor Training

• Part of 24 hour workshop focused on enhancing key leadership behaviors

• HPI concepts/tools integrated into the material▪ Relationship between error rates and cognitive modes

with examples from everyday life that are understood intuitively by FLS

▪ Recognition of error likely situations through theory and video exercises

▪ Tools for interactive pre-job briefings, task previews & “time outs” are reviewed & demonstrated

▪ Role play exercises on real job situations

29

Error Prevention Success Stories

• Increased use of “Time Out” practice• Deployment of HPI event investigation software

in selected investigations• Increased volume of procedure change requests

30

Lessons Learned

• Introduce new faces and use engaging speakers • Integrate HPI under ISMS umbrella to avoid

“new program of the week”• Team training for general employee orientation

HPI Training Panel Workshop – Hanford

Experience

Stephen WalterProject Environmental Safety & Health Bechtel National, Inc.Hanford Waste Treatment and Immobilization Plant

Presented September 12-13, 2006DOE Integrated Safety Management Best Practices Workshop

32

Changing the Paradigm

It can be hard to change the way people think

33

Crucial Conversation

Crucial Conversation

Human Performance

Initiative

Human Performance

Initiative

Nuclear Safety and Quality

Culture

Nuclear Safety and Quality

Culture

Training opened to

supervision

Training opened to

supervision

DOE HPI - IntroductionDOE HPI -

Introduction

Selected Participants

Trained

Selected Participants

Trained

NSQI SteeringCommittee -

Formed

NSQI SteeringCommittee -

Formed

Champion SelectedChampion Selected

Gap Analysis conducted

Gap Analysis conducted

Incorporation into other training

Incorporation into other trainingSafety

RallySafety Rally

- ISMS

34

The Vision

35

Implementing Human Performance

• Human Performance training – external▪ 65 trained▪ 32 completed the 4 day HPI training▪ ES&H, Engineering, Construction, Quality,

Employee Concerns, Human Resources, Commissioning, Procurement

▪ Attended DOE HQ HP TTT▪ Sent 2 to INPO for Human Performance Lead

training

36

Training Inclusion

• Safety Rally to impart NSQI/HPI vision

• 6 hour orientation now includes HPI fundamentals concepts

• Industrial Safety Training courses are being developed to include critical attribute questioning

• Accident Investigators are being trained to use HPI tools

• Partnering with Bechtel Power on HP training

• Learning from others

37

Lessons Learned• With so many initiatives employees seek to understand the “why” –

what’s in it for me?• Abundance of resources and tools – select a focus

• Don’t recreate the wheel• Project specific examples to

show value• Benchmark – learn from

others successes and errors

• HPI will be a work in progress

• Implementing Human Performance is not free

• You don’t have to create a new program!