Synthomer, part of Yule Catto & Co plc, Polymers division, is a major
worldwide producer of synthetic latex and aqueous based dispersions. There are eleven
manufacturing operations across Europe, Malaysia and Saudi Arabia, covering a wide range
of polymerisation processes including bulk, suspension and emulsion technologies, as well
as various compounding techniques. Within the UK, a major site is in Stallingborough,
which opened in 1963 and currently employs around 200 people. Stallingborough produces
36,000 dry tonnes of latex per year of which 70% is exported and 50,000 wet tonnes of
dispersion products of which 30% is exported.
As a COMAH top tier site, safety and environmental issues are very high on the agenda.
As part of their safety management programme Synthomer first employed the services of HASTAM in 1992. Since then, Mike Thomas from HASTAM has run at least one course a year on the Stallingborough site as well as conducting an audit. The typical approach is for key Synthomer personnel to decide on the topic to be tackled, then work with Mike to update an existing or develop a new procedure. In the past this has covered topics such as risk assessment, hazard reporting (SCAR) and incident investigation.
Recognising
the importance of an HSE study which showed that human failings were the root cause of
over 80% of incidents Martyn Garner, Works Director at Stallingborough, decided that his
site should start looking at ways to influence peoples behaviour and attitudes to un-safe
acts and reduce LTA’s. Martyn wanted a simple tool that could be used by everyone on
site. A tool that showed quick results but at the same time would have long lasting
benefits as working practices evolve.
Stallingborough has had a long and successful relationship with Mike Thomas of
HASTAM and this idea was passed on to him. From Martyn’s original idea the cartoon
character SAM was born.
SAM is an acronym for Stop A Moment and the idea is that before anyone starts a task they stop and think to see if the task can be completed safely. If the individual does not believe the task can be completed safely, they stop and discuss their concerns with a supervisor or manager. The individuals’ monitoring of SAM is backed up by routine sampling by shift supervisor and managers, who also use the SAM card as a prompt to discuss any unsafe acts which they observe.
Prior to adopting SAM, a working party comprising Mike and key personnel from Stallingborough developed a set of key questions. Stuart Askham, the training supervisor became the champion of SAM. Following a pilot course for managers, every employee and contractor attended a two hour training and briefing session at which they were issued with their own SAM card. In the two months leading up to the introduction a poster campaign was introduced and on a weekly basis a new poster was displayed on the site notice boards to increase awareness. A significant number of safety improvements were made in the first month.
Commenting on the success of the SAM approach, Martyn said “ We were looking for something that was far removed from the already heavily-laden paperwork systems and wanted something quick and simple. The introduction has been a great success with SAM being on everyone’s lips and hopefully in their minds.
A great part of this interest has to come down to the pre-implementation publicity and training so that everyone was conditioned to the arrival of SAM.”
Martyn Garner (right), Works Director, and Stuart Askham Training Supervisor with SAM.
"SAM has been a welcome addition to the
Stallingborough workforce and, as the photo shows, he is now the first employee you will
meet when you visit the Stallingborough site. SAM has lots of
brothers who could be employed on your site to ensure everyone goes home after a days
work."
After the first year, total accidents were down to 71% of the pre-SAM total (frequency rate down from 25.64 to 11.14 per 100,000 hours worked). The one-day lost time accident rolling frequency rate is down from 1.09 to 0.67. The other big success was the contribution SAM made to general safety awareness with, for example, incident reporting up by 89% on the pre-SAM figure.
Stuart Askham, SAM's champion and best friend, said "SAM really is working here! He is the best safety initiative we've ever taken on site. In the early stages SAM helped to update SOPs. Although we audit SOPs, SAM highlighted differences between what we said and what we did. We do retrospective SAM interviews to bring home the need to constantly use SAM. So, if someone has an accident that person is interviewed using the SAM questions and in nearly every case we show that SAM would have stopped the accident. SAM is here to stay and I look forward to further success over the next 12 months."
SAM's Birthday
April 1st 2008 saw Mike back at Synthomer to join SAM in celebrating his
fifth birthday. Five years on, SAM is still seen as a success, but it was
time for a few small changes. SAM is now much more grown up and has been
kitted out in standard Synthomer gear.
Routine SAM interviews will continue, but with more emphasis on identifying root causes and management system failures which have led to unsafe behaviours. As part of this, trained SAM interviewers were briefed by Mike on a simple version of root cause analysis which will now be used following all SAM interviews. Improved, computer based remedial action tracking has also been introduced. Fully refreshed, SAM is now ready for the next five years!
Mike Thomas comments that Synthomer at Stallingborough typifies the HASTAM approach to consultancy. "Our key aim is to develop a long-term relationship with our clients where we develop a detailed knowledge of their philosophy and needs. We work in partnership to provide them with just the help they need, just when they need it. Every service is tailored to the specific needs of the individual client. I'm delighted that SAM has proved so successful and helped Synthomer to improve their safety record.
