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FATIGUE MANAGEMENT AT KUMBA ICMM FATIGUE MANAGEMENT WORKSHOP AUGUST 2011

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FATIGUE MANAGEMENT AT KUMBA

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About Kumba Iron Ore

Problem Statement - High Potential Incidents

Safety Health & Environment - Systems and Focal Areas

Fatigue Management – our 3 dimensional approach

Shared Learnings from Kolomela Mine

-

Improved Living Conditions

-

Fatigue awareness and Bio-Rosters

-

Fatigue Prediction and Detection – Prism & Astid

Next Steps - Lifestyle Planners

Conclusion

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About Kumba Iron Ore

Kumba’s Vision

Kumba is a leading value adding iron ore supplier to the global steel industry

Strategic Intent

Kumba is an African growth company that seeks to maximise total shareholder value sustainably through optimising the value of current operations and opportunities down the value chain, as well as executing growth projects with the potential of becoming a 70Mtpa South African and a 10Mtpa to 20Mtpa African iron ore supplier by 2020. Kumba executes its business in a way that cares for its people, communities and the environment in which it operates

Operations

Kumba currently consists of 3 mines (Sishen, Thabazimbi and Kolomela)

These are serviced by one port operation in Saldanha

Accolades from 2010 include:

Top performing mining company of the year in the Deloitte Best Company To Work For Survey and ranked 6th overall.

Runner up for the second year in the Sunday Times, Business Times Top 100 companies.

A best performer in the 2010 JSE Social Responsibility Index

Ranked fifth in the Ernest & Young Excellence in Sustainability Reporting Awards in 2010

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Problem Statement

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Policy 1. Policy, Leadership & Commitment

Planning 2. Risk & Change Management 3. Legal and other requirements 4. Targets, Objectives & Performance

Management

Implementation & Operation 5. Training, Awareness & Competence

6. Communication, Consultation & Involvement

7. Document & Data Control

8. Operational Control

9. Emergency Preparedness & Response

10. Contractor & Partner Management

Checking & Corrective Action 11. Incident reporting & Investigation

Management Review 12. Monitoring, Audits & Reviews

Fatal Risk Standards Risk Management Safety

Programme (S.R.M.P.) Safety Focus Areas

1. Principle Hazard Management & Fatality Prevention 2. Contractor Management 3. Leadership and engagement 4. Learning from

Incidents & best practice adoption The Enablers Leadership at all levels Leading indicators Operating Discipline

Zero harm as a value

Underpinned by three principles

Health Focus Areas

1. Fatigue Management 2. HIV/AIDS Management 3. Drugs & Alcohol

4. Health Risk Assessments

Environment Focus Areas

1. Remediation and Pollution Prevention

2. Rehabilitation, Biodiversity and Land Management 3. Water

4. Energy and CO2

5. Assurance

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Principle Hazard Management & Fatality Prevention Contractor Management Learning from Incidents & Best Practice Adoption Leadership and Engagement

Fatality prevention and LTIFR reduction driven by key strategic drivers

Health & Occ. Hygiene

Focus on principle hazards Engineered solutions as a base Move to simple and standard

procedures

Train, coach and mentor

Replication and enhancement of SSP Contractor Management system

Standardised approach to common

applications

Operating discipline

Proactive use of leading indicators

ICAM training and capability Learning from industry

Effective corrective action close-out Behavioural interventions e.g. VFL

Leadership and competence Empower management and

workforce

Address unacceptable risk tolerance Health Risk Management

Fatigue Management HIV/AIDS Management

Drugs and Alcohol Programme

Key strategic drivers

Health and Safety Strategy – pursuing Zero Harm

3 Principles: 0.22 0.12 0.07 0.12 0.05 0.00 0.05 0.10 0.15 0.20 0.25 2007 2008 2009 2010 2011

Significant reduction in LTIFR

LTIFR

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Key principles applied;

• risk-based

• multi-disciplinary

• integrated & systematic • holistic solutions

Fatigue Management – our 3 Dimensional Approach

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Awareness and Education

•Induction e-learning and face-to-face training. Lark and owl study done on the operators of mobile equipment.

Bio-rosters

•Unions and employees vote on a schedule designed to reduce fatigue

Predictive Monitoring Technology

•Bio-rosters are designed to limit fatigue but when overtime is added to the schedule it is monitored by an electronic fatigue calculator that tracks real time fatigue data on each employee., i.e. the Predictive Risk Intelligent Safety Module (PRISM)

Fatigue Detection

•Vehicles quipped with collision avoidance technology and ASTID (pilot underway).

Nutritional Supplements

•Employees have access to caffeine, energy drinks, water or energy tablets during their shift that further the employees ability to combat fatigue. A baseline study on energy drinks was done to determine their effect on sugar levels.

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After Home Ownership and Hostel Conversion

• Kolomela Project included construction of decent housing integrated into the town of Postmasburg

- 712 houses at 3 locations

• At Sishen, existing traditional hostels converted into self catering family/single units

Lifestyle – Improved Living Conditions

Kolomela

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Bio-rosters

Bio-rostering refers to the pre-emptive management of fatigue by taking individual

schedules and rearranging days and times to make them safer e.g. in a typical DDNN schedule, employees come to work 5 days a month with 0 – 3 hours sleep. This is equal to a BAC of 0.07 – 0.08. When the pattern is changed to DDXXNNN, this takes high risk fatigue out of the schedule.

Kolomela shift roster

Weeks / Crews MON TUE WED THU FRI SAT SUN Hours worked

1 D D - - N N N 48

2 - TR (Mining) D D - - - 36

3 N N - - D D D 48

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Proactive and predictive fatigue management tool

• Monitors and identifies fatigue risk on an individual basis

• Assesses ‘Fit for Duty’ at clock-in and predicts fatigue risk for the shift

• Scientifically validated Alertness Test for secondary affirmation of performance

• Provides for inclusion of off-the-job fatigue-related factors

• Provides feedback process to track fatigue mitigation actions

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Fatigue Detection -

ASTiD

Kolomela are piloting the Advisory System for Tired Drivers (ASTiD). Astid analyses driver/vehicle interactions through steering corrections. It is built on sound scientific research into sleep and sleepiness by Loughborough Sleep Research Centre world renowned for its work into the effect of driver fatigue.

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LIFESTYLE EVENT NOTIFICATION SYSTEM

(LENS)

USES PERSONAL PLANNERS AND COMMUNICATION DEVICES TO PROVIDE NOTIFICATIONS THAT WARN OF OR COUNTERACT FATIGUE

LENSmobil

for Smartphones

LENSplanner

for Home Use

LENSpocket

to Carry on Person

Next Steps - Lifestyle Event Notification System (LENS)

Considering the use of personal planners and communication devices to warn and counteract fatigue

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Conclusion

A successful programme requires;

• Leadership commitment and resource allocation • A risk-based approach

• Multi-disciplinary teams seeking integrated, holistic solutions

• Total involvement and engagement of all stakeholders (employees, unions, families, service providers and communities)

……..take control, take charge!”

Wellness

Fatigue

Diet Sleep

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References

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