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Joint Overall Winners of the 2003 Workplace Safe Awards
Australian Paper and Downling's Onsite Engineering

(L to R) Simon Talbot of Australian Paper and Bob Dowling of Dowling’s Onsite Engineering

Australian Paper also won a Gold Award for ‘Best solution to an identified workplace health and safety issue’. It operates two world-class paper mills and employs around 750 workers.

Australian Paper’s safety teams/committees designed, manufactured and patented a new method for the safe and effective movement of staked loads. This integrated project is significantly improving the safety of forklift operations at the company’s Tasmanian mills and is in the process of being exported to the world paper industry.

Joint Overall Winner, Dowling’s Onsite Engineering, won a Gold Award for ‘Best workplace health and safety initiative in small business’.

Dowling’s is a site-based engineering company with 15-20 workers. It competed for and won a tender with the safest concept for the demolition of two old concrete meal silos at Australian Cement Holdings, Railton.

The company designed and developed a round working platform, round track and spreader beam specifically for this project. The innovative components eliminated scaffolding and other potentially hazardous work areas. Spillage, manual handling strain and back strain were eliminated or minimised.

Best solution to a workplace manual handling hazard
Gold Award: Hobart Ports Corporation, Hobart

Back (L to R): Matthew Johnston, Teresa Derrick, Jamie Bone, Matt Oddy Front (L to R): Kevin Badcock, Paul Woolley, Lisa O'Brien, Peter Coad, Tim Jones

Hobart Ports is a state-owned company operating shipping and cargo services as well as a cold storage centre. Hobart Ports identified a hazard in the requirement to manually ‘hook on’ metal straps and chains to break-bulk cargo loads. The hazard was addressed through the design and implementation of a cargo lifting platform and frame.

In addition to reducing OHS risks the new apparatus addressed many procedural and economic concerns, providing a wide range of benefits to the corporation’s overall operations.

The innovation was developed and manufactured by shop floor workers and supervisors involved in the manual handling operation. Provisional international patents have been taken out on the device and Hobart Ports is confident it could be used to increase safety, reduce waste and improve productivity in many ports around the world.

Best solution to a workplace manual handling hazard
Silver Award: Andrew Walter Constructions, Austins Ferry

The Minister for Infrastructure, Jim Cox, presents Silver to Andrew Walter of Andrew Walter Constructions, Austins Ferry

Andrew Walter Constructions is a civil construction company employing approximately 30 workers.

Following concerns raised by workers and a risk assessment regarding the need to manually operate a side conveyor on road maintenance machinery and the potential for back injury, the company purchased an air ram attachment. This attachment, once fitted to the road maintenance machinery, eliminated the need for the operator to climb in and out of the cabin as well as the need to manually move the conveyor.

Feedback from workers has been very positive with no further reports of back strains. As well, the company was able to see that its Internal Management System, which outlines a process whereby any worker can raise a Safety Improvement Report, worked effectively.

Best solution to a workplace manual handling hazard
Bronze Award: Temco, Bell Bay

The Minister for Infrastructure, Jim Cox, presents Bronze to Mark Ringsgwandl of Temco, Bell Bay

Temco employs about 280 workers in its ferro alloy production plant.

Risk assessment identified a potential for manual handling injury in the lifting of mild steel sheets weighing 30 kgs each in the Temco electrode case-making workshop.

Several arm and wrist injuries had been experienced by workers and problems were identified with workflow, machine accessibility, the weight of the steel sheets and the repetitive nature of the tasks.

Temco modified its case-making workshop, individually tackling each operation in the process, applying mechanical solutions and developing a unique, and safer, system.

Best solution to an identified workplace health and safety issue
Gold Award & Joint Overall Winner of the 2003 Workplace Safe Awards:
Australian Paper, Wesley Vale

L to R: Ron Sushams, Eddy Hodges and Simon Talbot from Australian Paper, Wesley Vale

Australian Paper operates two world-class paper mills and employs around 750 workers.

Australian Paper’s safety teams/committees designed, manufactured and patented a new method for the safe and effective movement of staked loads.

This integrated project is significantly improving the safety of forklift operations at the company’s Tasmanian mills and is in the process of being exported to the world paper industry.

Risks associated with poorly clamped paper have been eliminated, as have risks of manual handling strains and sprains for forklift operators and risks associated with pedestrian access to forklift areas.

Poor night time and periphery visibility have been reduced with the assistance of infrared cameras and dual monitors on forklifts. The amount of forklift traffic in the warehouses has also been reduced by 33 per cent.

Best solution to an identified workplace health and safety issue
Silver Award: Hobart Water, Goodwood

The Minister for Infrastructure, Jim Cox, MHA, presents Silver to Brett Grimston of Hobart Water, Goodwood

Hobart Water supplies bulk water to eight councils in southern Tasmania and employs 70 workers.

Much of Hobart Water’s work is undertaken in confined spaces. Risk assessments identified a lack of visual identification of the safe entry requirements at 230 locations.

A program was developed and implemented for a rating system that was used to individually assess each confined space. A register of entry requirements was developed and the mandatory requirements for entry identified. The confined spaces were then plotted on Field Books using modern technology and modification works were prioritised.

Entry requirements are now visually identifiable on a sign that incorporates the entry category rating and all confined space locations are available electronically to field workers. Workers were fully trained in both confined space entry and in the new rating system.

Best solution to an identified workplace health and safety issue
Bronze Award: Bonlac Foods Limited, Spreyton

Ian Langmaid of Bonlac Foods Limited, Spreyton, is presented with Bronze by the Minister for Infrastructure, Jim Cox, MHA

Bonlac Foods produces dairy products and employs approximately 170 workers.

Using a pro-active hazard identification and risk assessment program, the changing of filters on a powder silo baghouse at Bonlac’s dairy foods processing plant was highlighted as a hazard.

Workers had been required to enter the silo to identify any damaged bags and assist another operator outside the silo to remove them. Hazards included potential for falls, awkward lifting of the two-metre-long bags, and working at height in a restricted area.

Consultation with operators and engineers resulted in engineering modifications. Filter cages were replaced with a new design and a support bar was added, eliminating the need for an operator to enter the silo. A suitable access platform was also designed, built and fitted and the doors modified to allow clear, safe access to the filters.

Many benefits were gained, including improved relationships between workers and employers, an increased profile for safety issues and workers are now undertaking filter changes in a safe manner.

Best workplace health and safety management program
Gold Award: Norske Skog – Boyer Mill

L to R: Alex Terhell, Nick Collins, Mick Cuppari, Shane Horton, Kim Brown, Mark Marshall, David Mann, Yvette Edward, Leiz Moore and Verity Coulter of Norske Skog - Boyer Mill, with their Gold Award.

Norske Skog’s Boyer Mill produces approximately 280,000 tonnes of newsprint paper for the Australian market and employs about 430 workers.

The Boyer Mill has developed a comprehensive health and safety system that is integrated into the overall running of the mill and which is a core part of how the Mill does business.

The Mill identified a need to reduce lost time injuries and workers compensation premiums while also maximising the health and safety of workers and embedding responsibility for OHS at all levels of the organisation.

In the late 1990s a comprehensive OHS management program was implemented. At its core is consultation with and participation from workers, leaders, the OHS council and other stakeholders. The system is subject to continuous improvement with excellent results including: creation of a proactive, healthy and safe culture; a decrease of lost time injuries to zero in 2002–2003, significant reductions in workers compensation premiums and National Safety Council of Australia five star accreditation for three consecutive years.

Best workplace health and safety management program
Silver Award: Skilled Engineering Limited, Camdale

The Minister for Infrastructure, Jim Cox, MHA, presents Silver to Richard Glover of Skilled Engineering Limited, Camdale

Skilled is a contract labour hire and group employment company which has about 1500 workers.

The protection of Skilled’s workers is paramount to its industry as the company’s major asset is its people.

The diversity of worksites involved led to Skilled ensuring that risk exposure and assessments were conducted on all sites prior to workers being placed.

In 2002, Skilled decided to obtain industry best practice in OHS Management Systems. To do this it introduced the criteria for OHS excellence by meeting the Australian Standards OHS Management Systems (AS4801-2001).

Skilled was audited in 2003 by NATA Certification Services International and received accreditation in March. Skilled is the only labour hire company in Australia to have achieved this level of accreditation.

Regular external auditing will ensure Skilled maintains its accreditation and that it continuously improves its system with the goal of achieving a zero injury rate.

Best workplace health and safety management program
Bronze Award: Motors Pty Ltd, Statewide

The Minister for Infrastructure, Jim Cox, MHA, presents Bronze to Harold Smith of Motors Pty Ltd

Motors is Tasmania’s largest motor vehicle and truck sales, service and repair dealership. It employs 450 workers at 10 sites located statewide.

Motors developed a basic safety management program into an integrated, comprehensive system that has delivered record results.

Motors first introduced its OHS program in 1996 to address an unacceptably high number of workplace accidents and injuries, the resulting loss of productivity and the spiralling cost of workers compensation premiums.

Increased focus was placed on OHS in 2000 with new strategies developed, This included renewed emphasis on safety awareness and manual handling training for workers, safety leadership training for managers and continued emphasis on safety auditing.

An OHS coordinator was appointed in 2002 to upgrade the already successful program and implement a new safety management program.

The new system is specifically tailored for the motor industry and places heavy emphasis on hazard identification, risk assessment and risk control along with a continued focus on safety awareness training. The system is available to all workers through the company’s computer network.

Best return-to-work program
Gold Award: Cradle Coast Water, Forth

L to R: Lyell Aherne, Wayne Smith, Casey van Eysden, Michael Higginson and Peter Williamson of Cradle Coast, Forth with their Gold Award

Cradle Coast Water supplies bulk water to six north west councils and employs 27 workers.

Cradle Coast Water enhanced its safety system by developing a comprehensive return-to-work program in consultation with workers and other stakeholders.

A serious injury suffered by a worker in 2002 brought to light the need for updating the company’s return-to-work and induction processes.

Cradle Coast was able to prepare a tailor-made return-to-work program for workers in consultation with stakeholders. The ultimate goal was to get the worker back to full-time work but to do so with complete job satisfaction. This was particularly important when it was realised the worker could not return to his original position. This goal was achieved following contributions from all stakeholders and has led to a greater emphasis on manual handling training for workers and contractors.

Best return-to-work program
Silver Award: Cripps Nubake, Glenorchy

Craig Ackerly of Cripps Nubake, Glenorchy, receives Silver from the Minister for Infrastructure, Jim Cox, MHA

Bread manufacturer Cripps Nubake employs 165 workers. It modelled its innovative rehabilitation and return to work program on a previous Workplace Safe Awards Gold winner’s program.

The program provides an integrated rehabilitation process to facilitate an early and safe return to normal life activities, including meaningful employment. Any worker who sustains an injury, illness or disease, whether it occurred as a result of work or not, has access to an early and appropriate rehabilitation assistance to ensure the fullest possible recovery.

The program has been developed and moulded over a number of years using a consultative approach that includes the company’s safety committee, input from injured workers, the management team and various professional organisations and external consultants.

The program is reviewed annually to ensure the needs of incapacitated workers are met effectively and to verify the program continues to meet legislative requirements. Suggestions from workers and associates are also included during the review process.

Time lost due to traditional return to work intervention strategies has been reduced dramatically from a total of 456 days per year in 1999–2000 to 61 days in 2002–2003.

Best return-to-work program
Bronze Award: Cascade Brewery Company Pty Ltd, South Hobart

The Minister for Infrastructure, Jim Cox, MHA, presents Bronze to Max Burslem of Cascade Brewery Company Pty Ltd, Hobart

Cascade Brewery is Australia’s oldest brewery. Its 68 workers produce malt, beer and related products as well as fruit juice, ciders and syrups.

The rehabilitation and return-to-work program established within the company’s health and safety framework meets all of the requirements under current legislation. Importantly it contains procedures beyond normal practice, such as the application of the program to injured or ill workers, whether their condition is work-related or not. The program is also designed to ensure return-to-work happens as soon as possible in consultation with the company, the worker and the worker’s doctor.

The plan takes into account fitness for defined duties over an agreed timeframe and, when appropriate, the plan includes retraining for alternative duties on either a temporary or permanent basis.

Workers, insurers and external rehabilitation consultants were widely consulted in the development of the program and each program is unique to the particular worker involved. The program’s success depends on excellent communication between all stakeholders involved.

The program has resulted in minimal delay in developing and establishing a tailored workplan designed to meet an individual’s capability and the work available.

Best induction program
Gold Award: Mary Ogilvy Homes Society, New Town

L to R: Jill Geeves, Jo Hardy, Cassandra Van Gray of Mary Ogilvy Homes Society, New Town, with their Gold Award

The Mary Ogilvy Homes Society is a not-for-profit aged care facility catering for 73 residents. It employs approximately 90 workers.

The Home’s induction program includes a significant emphasis on OHS and in particular the principles of Duty of Care.

The induction program has three steps:
1. Initial introduction and orientation
2. Manual handling training with an accredited physiotherapist, and
3. A buddy shift with an experienced work colleague.

The program, which was developed in consultation with workers, provides a multi-faceted approach of organisation OHS requirements as well as the specific needs of each worker.

The program is also evaluated on an individual basis to ensure it continues to meet the needs of new workers.

The program is integrated into the overall operations of the Home and has seen a decrease in workers compensation claims and a reduction in the Home’s insurance premium of approximately 1.5 per cent from 2002 to 2003.

There has also been an increased understanding of Duty of Care and a general heightening of awareness and concern for OHS issues.

Best induction program
Silver Award: Caterpillar Elphinstone Pty Ltd, Burnie

Mark Jacklyn of Caterpillar Elphinstone, Burnie, receives Silver from the Minister for Infrastructure, Jim Cox, MHA

Caterpillar Elphinstone employs about 500 people in its underground mobile mining equipment manufacturing and marketing business.

Caterpillar’s safety induction comprises a vital component of the OHS management system and is fully integrated.

The safety induction covers all OHS legislation requirements and is a staged induction process taking a number of days to complete. Regular reviews are incorporated to ensure the health and safety of all new workers, contractors and others.

The program uses a dynamic and systematic approach to ensure all inductions are accurate, and to assist workers and contractors to enter and work safely within Caterpillar Elphinstone.

The induction program has had a considerable impact on workplace injuries with a 22 percent reduction in lost time injuries, a 53 percent reduction in medical treatments and a 30 percent reduction in the severity of injuries.

Best induction program
Bronze Award: Country Club Resort & Country Club Villas, Launceston

Sandra Brown of Country Club Resort and Country Club Villas, Launceston, receives Bronze from the Minister for Infrastructure, Jim Cox, MHA

This tourism and hospitality business employs 430 workers at two sites in a wide range of work activities.

The Country Club has developed a structure of induction training and competency assessment to reduce the risk of workplace injury/illness and has created a greater awareness among all worker groups of their own OHS responsibilities.

The organisation considers induction as applying not only to new workers but also to the transfer of workers to new work areas or training required following the introduction of new plant or processes.

Feedback from workers and active participation in contributing to the identification of hazards has demonstrated the success of the organisation’s induction program.

Best training program
Gold Award: TNT Express, Tasmania Pty Ltd, Montrose and Breadalbane

L to R: Roger Menzie, Jan Marchant and Peter Wicks of TNT Express with their Gold Award

TNT Express provides local, regional and global express freight services to and from more than 200 countries. It employs 50 workers throughout the State.

TNT Express’s backcare program has assisted the company to reduce the number of manual handling injuries suffered by its workers.

The company has worked to re-educate its workers through a variety of programs that create an environment where safety is the paramount consideration in any decision or task undertaken. The backcare program is part of this.

Statistics showed that 66 per cent of lost time injuries are sprain and stain injuries in the back and neck. These were mostly the result of poor manual handling skills.

The backcare program educates workers about the basic principles involved in safe manual handling, makes them aware of their own safety and that of their workmates, and gives the workers the skills and knowledge to avoid manual handling injuries.

TNT Express used the Investors in People standard to achieve its goals In its first year in the southern region the program contributed to a six per cent reduction in the number of back injuries. Further reductions are expected this year.

Best training program
Silver Award: Cripps Nubake, Glenorchy

Craig Ackerly of Cripps Nubake, Glenorchy, receives Silver from the Minister for Infrastructure, Jim Cox, MHA

Cripps Nubake employs 165 workers in its bread manufacturing business.

The company’s innovative training program embraces all aspects of safety and is based on its Accredited Quality Management System.

A thorough induction is the cornerstone of the program and all workers and contractors are required to undergo induction training. All workers are also re-inducted each year to re-focus them and ensure that basic safety and operational guidelines are reinforced on a regular and systematic basis.

Photomaps are used and serve as valuable visual training aids.

Some highlights of the training program include on-on-one training against documented tasks, on and off-the-job training, integration of safety into all standard operation procedures, worker involvement and sign-off on competencies, question and answer verification of understanding, annual competency reviews, and training for specific needs.

The training program has contributed to drops in injury rates, with back injuries dropping by 18 per cent over the past three years. Upper arm and elbow injuries have dropped 70 per cent in the same period and wrist injuries have dropped by 67 per cent.

Best training program
Bronze Award: Motors Pty Ltd, Statewide

Harold Smith of Motors Pty Ltd, Hobart receives Bronze from the Minister for Infrastructure, Jim Cox, MHA

Motors is a motor vehicle sales, truck sales, service and repair dealership employing 450 workers statewide.

Motors developed a comprehensive safety awareness manual handling training program in PowerPoint format to specifically address issues in the motor industry.

Together with hazard identification, risk assessment and risk control strategies, the training program has been a vital part of Motors’ overall strategy and has had a marked effect in reducing accident and injury rates by creating greater awareness of safe work practices.

The program includes responsible officer/manager/supervisors, safety committee and worker OHS training courses.

The current safety awareness and manual handling program for staff training is a major upgrade of that previously used. It was prepared in Tasmania in 2002 and has been successfully used by workers in Tasmanian and Melbourne dealerships.

The PowerPoint presentation format is versatile and was prepared using staff feedback and consultation. It has narration and guides participants through 112 slides, a 32-page worker safety manual and an 85-question multiple-choice questionnaire.

A new worker can successfully complete the training on day one.

As a result of this program Motors has experienced a drop in workers compensation claims from $451,986 in 1999–2000 to just $6,068 in 2002–2003.

Best workplace health and safety initiative in small business
Gold Award & Joint Overall Winner of the 2003 Workplace Safe Awards:
Dowling’s Onsite Engineering Pty Ltd, Wesley Vale

L to R: Karen Bell, Rob Dowling, Bob Dowling and Michael Bingham of Dowling's Onsite Engineering Pty Ltd, Wesley Vale with their Gold Award

Dowling’s Onsite Engineering is a site-based engineering company with 15-20 workers.

Dowling’s competed and won a tender with the safest concept for the demolition of two old concrete meal silos at Australian Cement Holdings, Railton.

The two silos had been redundant for two years and were clearly becoming unsafe and putting personnel at risk.

After careful consideration, a method was developed to demolish the silos starting from the top and working down. The health and safety initiative was to design a technique for safely cutting the silos into sections and lifting them down.

Dowling’s developed a round working platform especially for this project, which was bolted to the concrete silo walls. Cutting of sections was done on this platform using a concrete cutting machine mounted on a specially designed round track attached to the platform.

Once each section was cut, it was lifted down using a specially designed spreader beam. This beam was detached from the section once it was on the ground, the platform and the cutting track on the silo were moved to a lower level, the beam put back in place and then the process would begin again.

The specially designed components of the project eliminated the need for scaffolding and other potentially hazardous work areas. Spillage, manual handling strain and back strain were eliminated or minimised.

Best workplace health and safety initiative in small business
Silver Award: Valhalla Constructions Pty Ltd, Hobart

Steve Haremza of Valhalla Constructions Pty Ltd, Hobart receives his award from the Minister for Infrastructure, Jim Cox, MHA

Valhalla Constructions carries out the majority of its work in the various production departments of the Pasminco Hobart Smelter. The company employs about 11 workers.

It developed an OHS management system tailored to daily business activities carried out in the electrolysis department at the smelter, where work is focused on the maintenance and repair of critical fixed assets in the Cell Room. The tasks in this area are highly specialised and often take place while machinery is operational, which poses a significant safety hazard.

Prior to the development and implementation of this OHS management system, the workers’ only exposure to safety training was through Pasminco’s induction programs. While these were adequate for basic safety, the specialised nature of Valhalla workers’ tasks required a specific program aimed at their needs.

Working with an OHS consultancy firm, Valhalla developed an OHS management system that integrated into its management program. The system developed incorporated an Occupational Health and Welfare Safety Policy stating company policies and procedures. It also included an employee induction program, toolbox sessions prior to work stating each day, and risk assessments.

Importantly, the system both complements and builds on that of Pasminco Hobart. Valhalla aims to continually enhance and develop the system to ensure the safety of all workers.

Since its introduction, there have been demonstrated examples of a heightened awareness and commitment to safety among workers. The system will be monitored and improved on a continuous basis.