Case Study
Heavy Manufacturing
About the Customer
The Customer is a multinational organisation synonymous with operational excellence and leadership in metals processing and the production of bauxite, alumina, and aluminium products.
Customer Challenges
They have an unwavering goal of zero fatalities and zero serious injuries (life-threatening or life-altering injuries and illnesses).
Following a major corporate restructure, the Customer identified that it had various systems, software and reporting tools that were not fully integrated. Critical Risk data was not standardised, and a global view of critical risk management was limited.
They believed, quite rightly, that a standardised approach to fatality prevention with advanced reporting capabilities and predictive analytics would help achieve a sustainable fatality-free work environment.
The Customer recognised that a proven, robust system was required to achieve zero fatalities and zero serious injuries in a global organisation that operates in many different countries with vastly different cultures.
Forwood Solution
After a thorough global assessment and external discussions with other corporations using the Forwood Critical Risk Management (CRM) System, the Customer decided that CRM was the best solution to assist in preventing fatalities within their operations.
We moved fast. Forwood deployed the technical CRM system within six weeks and the Customer immediately began conducting critical control verifications in high-risk areas of their business.
The Customer’s Safety and Operational teams underwent a ‘train- the-trainer’ program and was deployed across 25 sites in nine countries in just over six months. With a standardized program, Forwood localized the delivery to each regional audience.
A key success factor in the rapid deployment of CRM is Forwood’s turn-key solution. The system comes complete with preloaded world benchmark critical control checklists aligned to each site’s risk profile. This approach accelerates the deployment and ensures more time can be spent on training and coaching rather than developing performance standards and critical control content over many months.
Outcomes Achieved
Over 150,000 verifications so far
The Customer set bold targets for critical control verifications. After conducting nearly 50,000 verifications in its initial year with CRM, the Customer more than tripled this number the following year. CRM enables standardization through a common understanding of the fatality risks and their critical controls.
CRM promotes safety engagement at all levels of the organization. High-quality data from each tier provides deep insights into risk exposures, enabling leaders to intervene with actions that prevent failures. The Customer has also found that CRM has increased control effectiveness so that in the event of an unexpected failure, controls are more likely to fail safely.
There have been many benefits from implementing CRM, but from a fundamental perspective, the Customer now has a common risk language among all employees and contractors. Forwood CRM has helped not only unify, but further reinforce the Customer’s commitment to preventing worker fatalities.
