The Critical Control Blueprint
Forwood established the first fully dedicated Critical Control Management Portal in 2011. This Portal and the blueprint methodology was initially deployed for BHP at the massive Minera Escondida Mine in Chile as a pilot program and shortly thereafter was rolled out to all BHP Copper Operations.
The New Accident Triangle
Not all incidents can lead to a fatality. Forwood has redesigned the Accident Triangle to incorporate critical controls and highlight the zone where fatalities occur. In a study that examined critical control failures within a large global mining company it was shown that there were approximately 200,000 critical control failures per fatal event.
The Solid Cheese Model
Forwood has recreated the traditional swiss cheese model by adding robust critical controls (solid cheese) that prevent fatalities and catastrophic events from occurring. This 'solid cheese' acts as verifiable barriers to give assurance that all critical controls are effective and that they will work as expected in the event of a failure.
The 3-Tier Verification Model
Forwood runs a 3-tier Verification Process to ensure that Critical Controls are in place where they matter most; on the shop floor. All Verifications are done immediately prior to any job commencing. Verifiers at every level confirm that the ‘path to death is blocked’ and that critical controls are robust and effective.