SAFETY

Case Study

Safety Standards are achieved through Proactive Awareness and Actions.

The Problem

Our client, a leading potash producer with over 20 percent of global capacity and operations spread across the globe, set an ambitious goal to be the safest mine in the world. They were experiencing a number of challenges impeding their ability to increase market share and deliver against an aggressive and safe production goal.

To meet their goal, they began a capital and operational expansion program at three of their sites. Large numbers of employees and contractors were hired, many of whom had limited experience in underground mining operations. While historical safety records were good, a significant uptick in the recordable incident rate raised concerns with senior management as to the robustness and quality of their current safety management processes and systems. Kalium Consulting was selected to develop and implement a safety improvement program to enable the achievement of the client’s vision of best-in-class safety performance.

We are beginning to make decisions in a team format following a structured process. It is evident there is significantly more of ‘we are running this place versus this place is running us’ attitude.

Client Project Management Lead

The Solution

  • Kalium Consulting partnered and developed a multi-phased approach, beginning with the assessment of the “current state.”
  • The scope of work included both the Mill and Mine Operations at the client sites and the associated Safety Program elements.
  • The second phase focused on identifying critical gaps in the important elements of the current safety program, addressing people, processes and management systems.
  • The last phase targeted the development and implementation of safety tools & processes – including checklists, hazard identification, risk assessment and mitigation, leading metrics, intensive training and coaching and the supporting management systems both at the Mine and the Mill to ensure sustainable safety results.
  • One our client’s sites had a large expansion program underway with over 1,000 contractor employees and a significant incident rate. Working closely with the management team, we developed consistent field level risk assessment processes and delivered one-on-one training, significantly reducing the incident rate year over year.

RESULTS

  • No recordable or first aids in the last five months at one of the sites
  • Another site achieved one million hours without a lost time injury
  • Over 50% reduction in injury rates at the third site with a major contingent of contractors who had no injuries