2019 HPRCT Conference

Domtar is a leading manufacturer of pulp and paper and fiber related products. With 10,000 employees in North America and Europe, Domtar operates over 30 production and distribution facilities. The company started a journey in 2013 to adopt HPI principles. Although improving the safety results was a prime objective, managers realized that human error was present in every aspect of Domtar’s business such as environmental impacts, product quality, reliability and productivity of equipment. This presentation will give an overview of the HPI journey, identifying key steps, successes and challenges.  Training and awareness: From 2013 to 2018 Domtar sponsored in-depth introduction to HPI principles and philosophy to all the key managers in all production facilities and corporate offices. The main gain was to create a common language across the corporation. The key challenge is to maintain the knowledge as staff turnover increases. A few sites did give training to all personnel with mixed results.  Investigations: In 2015, a new investigation process was rolled out. This methodology is based on the DOE Accident and Operational Safety Analysis Handbook. Domtar published its own Incident Investigation Handbook, incorporating HPI elements, and created a 3 level certification for investigators. The bronze level is intended for front line personnel for quick and accurate data collection from events as well as to develop interview skills. The silver level is targeted at managers, subject matter experts, and union representatives. Since 2016, over 250 silver investigators have been trained on the 4 part / 16 step investigation process. The gold level investigators are experienced individuals that serve as peer reviewers and off-site investigators.  Implementation of proactive tools: Education about proactive tools started with initial training and awareness. In 2017, Domtar launched leadership training for front line supervisors and incorporated a gradual introduction to HPI concepts and proactive tools.  Data collection and analysis: In order to support the corporation in various initiatives, including HPI philosophy, Domtar created software in 2015 to track business related events such as audits, investigations and continuous improvement activities. The HPI concepts were directly integrated into the investigation portion. The data can be extracted to see what are the key organizational weaknesses, what error precursors are most prevalent and create action plans accordingly.  Work organization: Senior leaders are knowledgeable and support the HPI philosophy. Each site has an HPI specialist, usually from the safety group. The corporation also mandated one person to be the corporate HPI specialist. This person was responsible for investigation training, supporting the investigation certification program, supporting the content of the leadership training and the development of the data collection software.  In summary, there are 3 key elements of success for Domtar in the deployment of the HPI philosophy:  senior leader’s belief in, support of, and acceptance of the total HPI methodology and philosophy, the adoption of HPI philosophy in all business areas, not only safety and the supporting data collection system which integrates key HPI elements.