Total Injuries at ProjectJan 2005 to date

3 3 3

57

12

2422

20

46

9

3 312112 20

10

20

30

40

50

60

Jan-05

Feb-05

Mar-05

Apr-05

May-05

Jun-05

Jul-05

Aug-05

Sep-05

Oct-05

Nov-05

Dec-05

Jan-06

Feb-06

Mar-06

FA

MA

78

13

48

ZERO Lost Time Incidents

45.1 45.1

20.8

29.9 30.5

38.8

52.0 50.949.1

65.1

55.0

48.8

0

10

20

30

40

50

60

70

80

90

Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05

YTD Accumulated Hours (X 10,000)

Monthly Hours (X 1,000)

Total Incident Frequency Rate

Company on Major Projects2005

Company on Major Projects2005

45.1 45.1

20.8

29.927.1

36.3

50.3 49.748.2

54.1

46.5

41.4

0

10

20

30

40

50

60

70

80

90

Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05

YTD Accumulated Hours (X 10,000)

Monthly Hours (X 1,000)

Total Incident Frequency Rate

With 52C Plant Start-up “Exposures” removed….

0

10

20

30

40

50

60

70

80

90

Month

Recordable Incident Rate

Total Incident Freqency Rate

Weekly Hours (X 1,000)

Project MTIFR: 37.9

Rebuild TIFR: 27.33

Company Hours & Incident RatesLast 2 Years

0

10

20

30

40

50

60

70

80

90

Month

Recordable Incident RateTotal Incident Freqency Rate

Weekly Hours (X 1,000)

Project Millennium TIFR: 37.9

Suncor 52C Fire Rebuild TIFR: 27.33

Company Work Hours & Incident RatesLast 2 Years

With Plant Start-up “Exposures” removed….

Oct 6th : M

eeting With Client

Oct 14th : Zero Tolerance Adopted

Oct 15th : Functional Safety Plan

Oct 19th : Aggressive A&D Policy

Oct 20th : Fresh Start /

Stand Down

Oct 25th : S

afety Incentive Program

Nov 24th : 2

nd Stand Down/Follo

w-Up

Nov 23rd : 1

st Safety Committe

e Insp

.

Nov 14th : 1st Safety Committe

e Mtg.

Mar

14

th : “Rem

embe

r Cha

rlie”

Feb 1

4th : I

nter

nal A

udit S

tart

(12 month moving TRIR)

Lessons Learned Lessons Learned

and and

2006 Improvement 2006 Improvement

PlanPlan

Things To Do:

0

10

20

30

40

50

60

70

80

90

Feb

-04

Mar

-04

Apr

-04

May

-04

Jun-

04

Jul-0

4A

ug-0

4S

ep-0

4O

ct-0

4N

ov-0

4D

ec-0

4Ja

n-0

5F

eb-0

5M

ar-0

5A

pr-0

5M

ay-0

5Ju

n-0

5

Jul-0

5A

ug-0

5S

ep-0

5O

ct-0

5

Nov

-05

Dec

-05

Jan-

06

Feb

-06

Mar

-06

Month

Recordable Incident RateTotal Incident Freqency RateWeekly Hours (X 1,000)

• Difficult to identify high-risk workers.

• Many low-experience workers (many competing projects).

• New Workers = New Foremen

IDENTIFYING HIGH-RISK WORKERS

SAFETY INTERVENTION PROGRAM MENTOR PROGRAM

LOW EXPERIENCE

WORKERS

CREW DISTRIBUTION

MORE INCIDENTS = MORE

INVESTIGATIONS

SUPERVISOR – INCIDENT INVESTIGATION

TRAINING

NEW WORKERS =

NEW FOREMEN

FOREMAN ORIENTATION TRAINING

REPORTS BY SUPERVISOR / IDENTIFY

TRENDS

-Intervention Program

-Mentor Program -Investigation Training

-Foreman Orientation

0

10

20

30

40

50

60

70

80

90

Feb

-04

Mar

-04

Apr

-04

May

-04

Jun-

04

Jul-0

4A

ug-0

4S

ep-0

4O

ct-0

4N

ov-0

4D

ec-0

4Ja

n-0

5F

eb-0

5M

ar-0

5A

pr-0

5M

ay-0

5Ju

n-0

5

Jul-0

5A

ug-0

5S

ep-0

5O

ct-0

5

Nov

-05

Dec

-05

Jan-

06

Feb

-06

Mar

-06

Month

Recordable Incident RateTotal Incident Freqency RateWeekly Hours (X 1,000)

• Fatigue a possible factor.

0

10

20

30

40

50

60

70

80

First 2 months 3rd and 4th Month 5th and 6th Month After 6th Month

Time From Hire Date

Nu

mb

er

of

Inju

rie

sInjuries from Hire Date2005

• 60% Currently Trained

• 84% End of April

• 100% End of May

Supervision Training

2005 Nature of Injury

34%

2%12%15%1%

1%

23%

7%

1%

1%

1%Sprain / Strain

Puncture

Laceration

Illness

Hemmorage

Fracture

Foreign Body

Contusion

Break

Blister

Abrasion

2005 Incident-Specific Lessons Learned

DEVELOP AND COMMUNICATE SAFE MANUAL MATERIAL HANDLING JHA

COMBINED = 50%BULK ARE PRECEDED BY “CRITICAL ERRORS”:

• EYES ON TASK• MIND ON TASK• LINE OF FIRE

WILL BE ADDRESSED WITH INTRODUCTION OF BBS

TRAINING WITH FRONT-LINE SUPERVISION:ENSURE ADEQUATE MANPOWER FOR TASKS

ENSURE ROTATION OF WORKERS

34%

2%

12%15%1%

1%

23%

7%

1%

1%

1%Sprain / Strain

Puncture

Laceration

Illness

Hemmorage

Fracture

Foreign Body

Contusion

Break

Blister

Abrasion

SPRAINS / STRAINS

34%

MATERIAL HANDLING

35%

BALANCE / TRACTION / GRIP

27%

STRUCK BY / AGAINST

23%

OVER EXERTION / REPETATIVE STRAIN

15%

Things To Do:

-Roll out B.B.S.

-Add job rotation to Supervisor Training

34%

2%

12%15%1%

1%

23%

7%

1%

1%

1%Sprain / Strain

Puncture

Laceration

Illness

Hemmorage

Fracture

Foreign Body

Contusion

Break

Blister

Abrasion

FOREIGN BODIES

23%

PRIMARILY IN EYES

FIRST INCIDENT REPORTED IN JUNE

EYE PROTECTION AWARENESS

CAMPAIGN TO BE LAUNCHED IN MAY

EDUCATION

EXPECTATIONS

SUPERVISION

WORKERS

ACCOUNTABILITY

Things To Do:

-Roll out eye protection campaign in May

34%

2%

12%

15%

1%

1%

23%

7%

1%

1%

1%Sprain / Strain

Puncture

Laceration

Illness

Hemmorage

Fracture

Foreign Body

Contusion

Break

Blister

Abrasion

ILLNESS15%

PRIMARILY EXPOSURE

ALL INCIDENTS BETWEENSEPT 22ND AND OCT 19TH

DURING RAMP UP OF PLANT

SHOULD BE ONE TIME ISSUE

SIMILAR FUTURE SITUATIONS

FORWARD LOOKING

EDUCATION

WORK WITH CLIENT TO ENSURE WORKFORCE

EDUCATED AND PROPER PROTECTIVE

MEASURES ARE TAKEN

Things To Do:

-Build training to roll out before next startup phase.

INEXPERIENCED WORKERS

34%

2%

12%

15%1%

1%

23%

7%

1%

1%

1%Sprain / Strain

Puncture

Laceration

Illness

Hemmorage

Fracture

Foreign Body

Contusion

Break

Blister

Abrasion

LACERATIONS12%

CONTACT WITHSHARP EDGE

38%

HANDLING SHARPMATERIALS

31%

STRUCK BY / AGAINST

15%

CONTACT WITHKNIFE BLADE

7%

EYES ON TASK / MIND ON TASK /

LINE OF FIRE

BEHAVIOUR BASED SAFETY

POOR PRACTICE

EDUCATION

EXPECTATIONS

SUPERVISION

WORKERS

ACCOUNTABILITY

0.000

0.010

0.020

0.030

0.040

0.050

0.060

0.070

0.080

0.090

Jan 7 Jan 14 Jan 21 Jan 28 Feb 4 Feb 11 Feb 18 Feb 25 Mar 4 Mar 11 Mar 18 Mar 25

Week Ending

# o

f F

LH

A's

pe

r H

ou

rField Level Hazard Assessments

Attitudes & Behaviour Eliminate All Risk

Self95%

Other People4%

Equipment1%

•Rushing•Frustration•Fatigue•Complacency

•Eyes not on task•Mind not on task•Line-of-fire•Balance, traction, grip

Major

Minor

Close Calls

Hazards

Major

Minor

Close Calls

Hazards with a Critical Error

SAFETY INCENTIVE PROGRAMSAFETY INCENTIVE PROGRAM

Safety Awards at Safe Work Hour Milestones

Communicate at Hire

Has Raised Awareness Toward Small Incidents

2nd Phase (Specific Act Rewards) Rolling Out Soon

Identifies workers that have had 2 or more injuries within one year; or 1 incident within the first month.

Safety awareness discussion Incident history review Incident frequency projection (“If you continue at this rate…”) Hazard recognition and personal responsibility Increase personal awareness of safety performance Worker-driven action plan

Hazard recognition training