We will reduce the company’s risk level (combination of frequency and gravity of incidents) by 22 per cent per annum up to 2024.
Our Management Board and the top management in the regions assume an active role when it comes to safety awareness. To improve communication with the individual regions, CEO Philipp Lehner, COO Walter Ritzer and Rogelio de la Rosa, Head of Corporate Health, Safety & Environment, regularly produce videos to teach all the employees around the world that safety is a top priority at ALPLA. To ensure these videos make it to everyone, they are translated into more than 20 languages and are shown at all the plants.
There are also monthly meetings in which relevant incidents and trends regarding safety are analysed as a way of ensuring that preventive measures can be implemented promptly and lastingly.
Zero as the ultimate goal
We have a vision of achieving an accident rate of zero. We have therefore further optimised the structure of our Corporate HSE team and of the regional teams in order to additionally boost ALPLA’s HSE performance and precisely track and monitor it. We also developed the HSE24 strategy comprising demanding targets and a clear plan of action to achieve zero accidents. The three main projects are:
- The introduction and improvement of LOTO (lockout-tagout), a series of procedures which ensure that machinery is switched off, is inoperable and, if necessary, is disconnected from the power supply, allowing maintenance and repairs to be performed safely
- Standardisation and review of the current risk assessments for machinery and activities
- Introduction of a new accident database
These topics are being implemented with a comprehensive safety awareness concept covering the following areas:
- Safety gemba walk
- Golden safety rules
- Activities to mark World Day for Safety and Health at Work
- Awards in recognition of outstanding safety measures
- Replacement of long-standing safety procedures
- Learning from safety-related incidents
- An increase in the reporting of near misses, unsafe behaviour and unsafe conditions by one report per employee per annum
Certification in accordance with international standards
Modern technologies, a highly qualified team, certification in accordance with international standards – ALPLA meets all the demands that global companies face. Our sites and production plants are certified in accordance with the following standards:
- ISO 9001 quality management system
- FSSC 22000 food safety management system
- ISO 14001 environmental management system
- ISO 45001 occupational health and safety management system
- ISO 50001 energy management system
- ISO 15378 management system for primary packaging materials for medicinal products
- SMETA 4P Sedex Members Ethical Trade Audit
We comply with international standards and legal regulations, and regularly train our employees to ensure that they are not only familiar with, but can also implement all the quality principles. We also continuously critically evaluate our quality systems and endeavour to make continuous improvements. We make the relevant information available and we proactively seek dialogue with our partners, customers and other target groups.
Our activities for healthy employees and safe jobs
As part of ALPLA’s comprehensive safety awareness, World Day for Safety and Health at Work was celebrated in all the regions for the first time in 2021, with more than 90 per cent of the employees taking part. Taking the Covid-19 rules in each of the regions into account, all kinds of events were organised around the world ranging from fire safety and first aid exercises to safety games using virtual reality. The HSE officers at the local level also presented preventive solutions and useful tools to the employees there.
Learning from incidents (unsafe practices, unsafe conditions, near misses or accidents) is of fundamental importance. This is why ALPLA developed a template which is completed in a structured way with all the key information following a safety-related incident. Knowledge regarding how such incidents come about is especially important in order for the company to be able to implement preventive measures around the world accordingly. This knowledge is therefore communicated in a summarised form to all the employees at our production sites. This keeps them up to date on what is happening around the world in their area of work and how everyone involved will (be required to) take action in the future to prevent such incidents.
Examples of good practice in the area occupational safety are also shared across all the plants around the world. As part of ALPLA’s operational excellence (OPEX) programme NEXT, all the good examples of occupational safety (and other OPEX topics) are collected and shared on a platform. The plants and regions upload examples to a platform according to a defined process and these are then regularly reviewed at the corporate level to guarantee the high quality of the practices shared. Plants with a high level of participation and quality contributions are recognised with rewards (recognition system). The platform allows for low-threshold interaction among the employees (e.g. automated notification when new examples are uploaded, a comments function, statistics) and promotes the global transfer of knowledge.
A stable, decentralised process has been established at the plants which involves the platform regularly being searched for new examples in order to be able to pick up and implement other people’s ideas.
A new accident database has been introduced to collate all the incidents around the world in a more structured way and analyse, examine and monitor them. Improvement measures for the entire company can then be systematically derived from this database. This platform allows all employees to report safety-related incidents (unsafe practices, unsafe conditions, near misses or accidents) quickly and simply, which helps us to increase the number of near misses and observations reported and prevent serious incidents from occurring in the future.
Safety training for all the employees is developed not only to meet statutory requirements or international standards, but also to communicate our vision of zero accidents and make everyone an important part of this goal.
Our e-learning courses were revised in view of the pandemic to make them more attractive and more interactive. ALPLA gave more than 88,000 hours of safety training in 2020.