Safety and health

In July 2008 Mineração Serra Grande (MSG), Brazil, acquired a Failure Mode and Effect Analysis (FMEA) system, prompted by a fatal incident which occurred on 12 February 2008. During the investigation into this accident, it was recommended that a tool to facilitate the identification of the basic causes of incidents was needed.

The FMEA is a procedure for analysing potential failures within a system of work and for classification of the effect of failures on the system. “Basically the system helps to identify the risks presented by these failures, before they result in accidents, and then to remove or mitigate these risks,” explains AngloGold Ashanti Manager: Safety, John McEndoo.

“MSG formed a project team, with a mechanical engineer and mechanical technicians to introduce the computer-based system. From repetitive failures and incidents with large risk potential, it analyses failures identifying basic causes,” explains Camilo Farace, General Manager: Mineração Serra Grande. “The system then recommends how to stop, or minimise such failure and incidences. These actions are also monitored by the team, and the relevant departments.”

The system was not introduced with cost-saving in mind – the focus was on improving occupational safety - but as a result, some expenses have been reduced. Secondary benefits of the implementation of FMEA include the increase of equipment availability, improved awareness of safety among operational and maintenance staff, and the reduction of repetitive problems. As an example, there has been a reduction in the number of fans replaced in the cooling system of Volvo trucks used on site and the number of problems experienced with the parking brake system of wheel loaders has also decreased. When analysing failures, however, the main focus is the safety items – any other benefits are secondary.

The system has also posed some challenges for the team. Says Farace, “We have faced some difficulties in terms of the analysis work at MSG. In some cases, we fail to determine the basic failure causes because employees are not yet familiar and comfortable with the tool. Employees do not always understand that the system is not there to blame them for accidents, but rather to get to the root causes of incidents and help to prevent future accidents. Besides the FMEA benefits, we have also been working with employees to achieve work practice improvements, and in the past few months there’s been great improvement. We believe that FMEA has been a great contributor to this progress, through technical and detailed analysis of incidences. Another indicator of this progress is a reduction in the number of incidences involving equipment, but with no physical injuries, in the last year as shown in the graph below.”

Material damages in 2008

In addition to the installation of the FMEA, MSG has a system called the Risk Management Programme (PGR – Programma de Gerenciamento de Riscos). This system involves a set of actions and procedures aiming to manage the risks associated with all operational activities through risk assessments, planning, training, implantation and utilisation of preventive procedures. These procedures are in compliance with Brazilian and international legal requirements.

“The risk programme is subdivided into several other programmes, directly aimed at managing the risks associated with all aspects of our activities. These programmes include a Hearing Conservation Programme, an Environmental Management Programme, and an Environmental Care Programme - to name a few,” says Farace.

The programme is periodically audited (internally and externally), and is certified in terms of OHSAS 18001, a specification that structures the implementation of an effective occupational health and safety management system; and ISO 14001, an environmental management standard. The FMEA has been integrated into the health, safety and environment programmes at MSG.

The Occupational Health and Safety management system (OHSAS) at MSG uses a process of risk management. This process is divided into five sections namely: policy, planning, implementation and operation, checking and corrective action, and management review.

In 2008, the Planning and Prevention of Losses training programme was reviewed by an external Brazilian safety specialist company. Through specific training of all Serra Grande’s operational staff, employees were prepared for the prevention of material, environmental or injury losses. This training programme was structured to emphasise to employees the application of the tools that are part of the PGR and increase the level of general risk awareness.

“It is always difficult as a management team to implement a new system and make a success of it immediately. The MSG team has kept the momentum of the project up and will continue to echo that safety is our first value,” concludes McEndoo.