Sibelco’s journey to ZERO harm GOSH meeting, 21th April 2016 Stiermerheide, Genk, Belgium An Buttiens, HS Director Sibelco Europe

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August 2014…

124.2

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Fatality: Contractor gets caught by rotating mill in High Performance plant

Direction of mill rotation

Position sensor the contractor wanted to check

Railing around engine block crossed by contractor

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Milestones Sibelco Europe 2011

• GFE (going for excellence) • Bradley Curve • HS charter en management system • HSE AUDITS

2012

• Top management commitment: Letter of Kevin Crawford and Jean-Luc Deleersnijder (27/6/2012)

2013

2014

2015

2016

• Sibelco Next

• Traffic safety campaign

• Next 2.0: sibelco Group

• GFZ Action plan role out

• Digital platform

• August 2014 fatality in high standards plant

• March : GFZ program launch

• GUARDING campaign

• Lagging > leading

• Compliance check GFZ standards • SSWM role out

• No Dust project (EU + NAM)

• Nov 2014 : Taskforce GFZ

• ICAM investigation • LOTO campaign

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Going for Zero Task Force

November 2014 – March 2015 2 members from every region: Europe, Asia, North America, South America, Australia Ops & HS

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Identified challenges:

In order to reach zero accidents we need to focus more on improving our safety culture, involvement and leadership. This will require

behavioral change. How to start ?

Rules, policies, guidelines, procedures… are in place but are we sure they are all communicated, implemented….? What is their impact on our objective to go for zero ? 26 minimum S&H system elements, some organizational and some technical. Do we have the right elements and are they captured in a way that facilitates behavioral and cultural change? We have our

Pressure on the frontline (plant/site managers) is high (e.g. quality, production, HR, legal, compliance…) creating difficulties to prioritize.

No Group wide approach but more Regional or Country or even plant specific approaches.

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First step

Internal survey External Benchmark

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External Benchmark…

8%

29% 39% 4% 22%

36%

20%

8

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Internal survey…

What is your most significant challenge in preventing injuries in your area of responsibility? What actions do you suggest Sibelco could undertake to assist you to eliminate injuries from your workplace? Do you feel you have sufficient resources to provide a zero harm workplace? Do you believe safety is the highest priority at Sibelco? Do you feel supported to make decisions that will improve safety but may cause negative impacts on production or profit? Do you feel Sibelco employees have enough knowledge to identify and control safety hazards and risks? Do you feel your plant and equipment has enough physical safety controls installed to prevent injury?

9

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Identified Elements for recommendation Visibly felt and aligned Leadership - Leadership Training at all levels and all functions Behavioral change through this Leadership as a safety value One program Strong focus on Catastrophic risks Same approach for Contractors Consequence Management Role of plant/site manager is key (role model) in engaging with the workforce. Enlarge HS knowledge, competences and skills. Integration in Job Descriptions, Performance evaluation & development (no bonus system) Pursue Plant Employee Feedback exercise Robust risk assessment/risk management program Learning from incidents Auditing is a substantial part of safety program Change Management: assistance of HR needed Impact on resources to reach goal Recommend separation/identification of GFZ expenditures - create an envelope to seperate GFZ Opex from achievement of financial targets across Sibelco Identify Quick Wins (Safety Day, Safety always as first point on the agenda,…..)

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Identified Elements for recommendation

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To Program elements Leadership at the top / clear management visibility Clearly describe what people are expected to do for safety

Monitoring performance

Implementing a H&S management system

HS ownership and involvement by ALL Confidence by all employees employees that company values H&S

Creating a safety culture

Operational integration via risk assessment embedding

Accountability and consequence management

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A Safe and Healthy Workplace. Going for Zero: The Sibelco Way

Visibly felt and courageous Leadership • Aligned (top to bottom) at all levels and in all functional domains • Behavioral Change • One Program • Consequence Management (positive & negative) • Strenghtening Role of Site Manager North America • Integration of Safety in HR-Tools for better HS Accountability

Bringing to the floor • Role of Site Manager is Key – Line Manager ownership • Behavioral Change and attitude (Safety from within) • Buddy system (care for each other) • All Sibelco employees, contractors, visitors are Safety Leaders • Same approach for contractors, visitors etc

Australia

Closing the Loop – Make Safety Sustainable • Auditing • Plant Employee Feedback Exercise per region defining gaps • Change Management • Resources

& & &

Focus on Catastropic Risks • Identify, investigate, manage and control catastrophic risks • Mining the Diamond

Enablers: Processes & Resources • Risk Management Program (Operational Controls & 26 Program Elements) • ICAM ( Incident Cause Analysis Method) • Allocate and quantify the necessary resources (people and Money) to meet our ambitions • Training Programs on Leadership & Change Management (leadership at all levels) • Clear description of what leadership means, what the expections are, which behaviour we want to see etc. • Clear measurements focussing on leading indicators

& 13

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Going for Zero: The Sibelco Way on a Bradley curve…

Focus on Catastropic Risks Closing the Loop (audit/feedback) Enablers: Processes & Resources Leadership

Bring to the floor

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Assessment Impact on existing programs

GFZ accelerates the implementation of the highest risks components of the existing pograms specificaly: No.

Element

1

Risk Management

2

Employee Training

3

Behaviours

5

Occupational Health (RCS objective guidance)

8

Inspections

9

Incident Management

10

Auditing

12

Performance Metrics

13

Employee Involvement

15

Fall Protection

16

Energy Isolation

17

Electrical Safety

19

Machine Guarding

22

Transportation/Vehicle Safety

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Assessment Impact on existing programs Existing programs include: 26 elements Operational Excellence RCS objective guidance (adopted Dec 2013) GFZ accelerates the implementation of the highest risks components of the existing pograms specificaly: No.

Element

1

Risk Management

2

Employee Training

3

Behaviours

5

Occupational Health (RCS objective guidance)

8

Inspections

9

Incident Management

10

Auditing

12

Performance Metrics

13

Employee Involvement

15

Fall Protection

16

Energy Isolation

17

Electrical Safety

19

Machine Guarding

22

Transportation/Vehicle Safety

Remaining elements will be continued to be implemented In the coming months Operational Excellence will be reviewed against the GFZ-program and adjustments will be recommended

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Proposed Action focus

Top Catastropic Risks identification and action plans

Introduce Behavioral Safety at all sites at any time

Develop a strategy to implement Root Cause Analysis for all actual and potential catastrophic risks – ‘Mining the Diamond’

Develop & role out Leadership Development Training

Get resources right allowing the whole organisation and certainly site managers to focus more on Safety.

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Pillars of a Safe Organisation

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Going for Zero program launch

Going for Zero is a safety improvement program that will deliver Operational Excellence – a safe and healthy workplace – to every Sibelco site.

It addresses the three components of a safe and healthy workplace: Safe plant and equipment Safe systems of work Safe behaviours

The Going for Zero vision is documented in our “Going for Zero – the Sibelco Way”.

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Safety: The Sibelco Way

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Dedicated GFZ capex budget (Sibelco Europe chart)

Budget defined in 2016+2017 budget: 14,5 MIO Euro

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Some impressions: March 2015 to date…

SSWM: Safety Starts with Me : BBS Same program in 5 regions - 20 languages – external & internal trainers

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Training & Company knowledge

One common methodology to investigate serious actual and potential (near miss) incidents.

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Effective safety campaigns Adopting a project management approach

• Method Multi-disciplinary project team Detailed project planning / timetable Project review cycle Focus and resources from Operations Site visits to gather good practice examples Site-based “Champions”

• Campaign materials Basis – Lifesaving Rules, GFZ Standards and site self-assessment checklists Toolbox for O(U)M, site managers, HS Toolbox talk for all employees Posters Videos Guidance materials High level launch communications

• Translation into 17 languages

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Provide tools: e.g. Traffic management plan

Guidance

Visio Tool

• Easy steps to develop TMP • Examples & best practices • Developed inhouse with traffic expert support • Standard format for every site • Easy to use • Developed inhouse Toon demo visio

Risk assessment on site

• 2015 Sites visit to support local teams • facilitates interaction between disciplines (operations, logistics, HS,…)

actions in SAM & Progress compliance scores

Implementation

Yury & Alexy (Russia) discussing traffic plan

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Add a 4th ‘P’ to People-Plant-Procedure: Promotion (Communication)

Video

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Plant visit: Safety guidelines

Everyone should register upon arrival in our plant In all our production areas, the minimum safety requirements are a helmet, safety glasses, safety shoes and a high visibility /fluo vest or clothing. If you enter a production areas, follow the instructions of your guide – keep together Keep distance from moving machinery and use the handrail when walking at stairs Please be aware of internal traffic (they have priority) and respect signs