(69c) 50 Million Safe Man-Hours without a Lost Time Incident – A Success Story

This paper describes the technical & behavioral systems and improvement initiatives Fatima Fertilizers Limited has successfully implemented in past 7 years to reduce the number and severity of their process incidents and which has improved the safety records of FFL to world class level. Below are the major results we have achieved so far,

1. No lost time injury since 2012.

2. 1^st fertilizer company across the globe to achieve 50 million safe man-hours.

3. Achieved “Excellence” in Process Safety Management by DuPont.

4. Zero Total recordable injury rate in 2019 so far

5. Plant on-stream factors improved from 80% in 2012 to 95% in 2018.

6. Production improved from 0.97 Million ton in 2012 to 1.4 Million ton in 2018.

7. Awarded Distinction by British Safety Council in International Safety Award in 2019.

8. Awarded by Royal Safety for the Prevention of Accidents (RoSPA).

The paper will describe the details of implementation process and maturing steps of systems on Behavioral aspects such as operating discipline, human factors, leading/lagging indicators and Technical aspects such as PHA, reliability forums, mechanical integrity & quality assurance, management of change etc. which resulted in achievement of such remarkable results.