Management Report & Annexes | Basic Information About the Group

11. Safety

Safety management is a keystone of corporate responsibility in the Bayer Group. We consider the prevention of accidents in day-to-day work, in the operation of production facilities, and on work-related travel and transportation routes to be a top priority. Our activities in the areas of health, safety, environmental protection and quality (HSEQ) are geared to ensuring the occupational health and safety of employees, contractors and suppliers on our company premises and under the supervision of Bayer, and the smooth and safe operation of our facilities. In this way, we also reduce running costs by avoiding damage and work disruptions.

At the Group level, responsibilities and framework conditions for HSEQ are regulated through appropriate ­directives. Operational responsibility lies with the boards of management/executive boards of the respective subgroups and service companies and the corresponding line organizations, who have their own management systems, committees and working groups to steer HSEQ. Continuous review and ­revision of directives and regular internal audits ensure that our HSEQ management systems meet the specific requirements in each case.

Occupational health and safety

The rate of occupational injuries with lost workdays at Bayer has been falling for several years. In 2013 we were once again able to report a reduction in injury figures thanks partly to intensive training and awareness-raising.

We record all injuries to Bayer employees requiring medical treatment that goes beyond simple first aid. These are indicated by the Recordable Incident Rate (RIR), which covers both injuries with lost workdays and those without. In 2013 this rate dropped to 0.47 cases per 200,000 hours worked (2012: 0.49) in the Group. This means that, in statistical terms, one recordable incident occurred for around every 425,000 hours worked.

The rate of recordable occupational injuries with lost workdays (LTRIR, Lost Time Recordable Incident Rate) also fell. In 2013 it stood at 0.26 (2012: 0.27).

Unfortunately, in 2013 we had to report the work-related death of a Bayer employee in Mexico and of a contractor’s employee in China.

Occupational Injuries[Table 3.11.1]
2009 2010 2011 2012 2013
Occupational injuries to Bayer employees with lost workdays (LTRIR*) 0.40 0.34 0.31 0.27 0.26
Recordable occupational injuries to Bayer employees (RIR*) 0.62 0.62 0.56 0.49 0.47
Fatal injuries (total) 4 4 3 2 2
of which Bayer employees 4 4 2 2 1
of which contractor employees** 0 0 1 0 1

* The values up to 2010 were calculated on the basis of the former MAQ values and do not include work-related illnesses.

** employees working for third parties whose accidents occurred on our company premises and under Bayer supervision

The injury figures varied both within individual regions and according to subgroup/service company.

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Online annex: 3-11-1

Recordable Occupational Injuries (RIR) to Bayer Employees by Region[Table 3.11.1-1]
20122013
Europe0.210.72
North America0.560.49
Asia/Pacific0.540.20
Latin America/Middle East/Africa0.530.40
Total0.490.47

The unusually sharp increase in the RIR injury rate in Europe is currently being closely investigated.

Since 2012 workplace-related illnesses have been recorded separately from legally listed occupational diseases and are included in the LTRIR parameter. In the reporting period, six new cases of illness directly attributable to work-related factors were recorded throughout the Group. We report such cases when they have been diagnosed and officially recognized by a medical officer.

As in previous years, we hardly recorded any sector-typical accidents involving contact with chemicals in 2013. The absolute number of injuries declined further. A significant proportion of our work-related accidents and injuries relates to traffic accidents. In the previous year (2012) these were even at the top of our list of injury statistics. As a result, road safety was the focus of many programs and training courses in 2013.

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Online annex: 3-11-2

Safety in motorized and non-motorized transport was also a central issue at the HealthCare sites worldwide, along with accidents caused by tripping, slipping and falling, as they account for most occupational injuries with lost workdays at HealthCare. Various measures and campaigns to prevent accidents on the road and on company premises were therefore carried out at many sites in 2013. Dedicated training courses and activities were also used to raise awareness in other areas of occupational safety such as workshops on the safe handling of hazardous substances for employees at various Chinese sites.

Road safety was also a big issue at CropScience in 2013, especially in training sessions for employees in Brazil, Colombia, Chile and Venezuela, and in several Asian countries, where motorcyclists in particular were given instruction. In a monthly “QHSE Update,” CropScience publishes up-to-date information and advice for its employees worldwide.

In 2013 MaterialScience once again called on its employees to submit their suggestions for the subgroup’s own CEO Safety Award. Measures implementing the winning entries will be rolled out worldwide at MaterialScience in 2014.

On the basis of a 2012 employee survey on HSE (Health, Safety, Environment) performed at Bayer Corporation in North America and at MaterialScience worldwide, all MaterialScience sites drew up action plans by the end of 2013. The goal is further improvement in occupational safety and the corresponding HSE management systems.

At the annual Group-wide Safety Day in September 2013 there was also a particular focus on correct road safety procedures.

Process and plant safety

Through the Group-wide process and plant safety (PPS) initiative, Bayer is continuously working to improve the safety culture and corresponding standards in plants and laboratories and to optimize safety technology.

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Online annex: 3-11-3

By the end of 2012, the process and plant safety initiative had provided training to approximately 26,000 production and technology employees and had led to the introduction of a standardized risk assessment including a catalog of measures. Based on the experience gained from these initial training courses, work began in 2013 on preparing teaching materials to enable the long-term continuation of the training program using both traditional and web-based training. To maintain the standard achieved in the long term, the process and plant safety training program will be firmly established in the subgroups’ HSEQ management systems.

Further standardized KPIs, such as Loss of Primary Containment (LoPC), were also prescribed for all Bayer plants. LoPC refers to unsafe conditions in production facilities, for example chemicals leaking from their primary container such as pipelines, pumps, tanks or drums. LoPC was introduced as an early indicator. We use the associated rate (LoPC Incident Rate) to determine the number of LoPC incidents per 200,000 working hours in areas relevant to plant safety. The LoPC Incident Rate for 2013 was 0.35 (2012: 0.38).

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Online annex: 3-11-4

Every incident reported is carefully analyzed with respect to its causes. The result of the cause analysis is publicized across the Group to heighten the safety awareness of employees. The reporting level is set so low that even material and energy leaks that have no impact on employees, neighbors or the environment are systematically recorded and reported. This approach is in line with our commitment to maintaining the integrity of our facilities at all times. As expected, the evaluations from the first few years have indicated areas where there is room for further improvement in the safety of existing facilities. The introduction of both this parameter and the global training program mentioned above is helping us to raise awareness of the significance of minor leaks and releases.

The Bayer Group Regulation “Process and Plant Safety” stipulates uniform processes and standards. The ­methods and criteria for identifying and assessing the risks posed to people and the environment by plants and processes underwent further development and were globally standardized.

The Bayer Group’s competence center for process and plant safety, together with the Group HSEQ ­Platform for Process and Plant Safety, is managed by Technology Services. This comprises three regional competence centers, which are located in Leverkusen, Germany; Shanghai, China; and the Baytown and Kansas City sites in the United States.

Transportation safety

A central objective of the Board of Management is to make transportation safety a very high priority within the Bayer safety culture. The Bayer Group Regulation “Transportation Safety” specifies procedures that ensure that all transported materials are handled in line with applicable regulations and the materials’ hazard potential. Logistics service providers are to be selected following a defined procedure, and their fulfillment of safety and quality standards is to be assessed regularly. The regulation requires every organizational unit concerned to appoint people who will be responsible for implementation.

A Group-wide Transportation Safety Platform has been set up that is chaired by each of the subgroups in turn. In 2013 the focus of the platform’s activities lay, for example, on sustainable training tools for transportation safety, reviewing internal instructions and evaluating and selecting our logistics service providers. This was documented in corresponding HSEQ targets. As part of our Responsible Care™ activities, transportation safety instructions are also being drawn up for non-hazardous materials. This goes beyond what is required under transportation legislation.

The transportation safety management of the subgroups is part of the audit system of the Bayer Group detailed in the Bayer Group Regulation “Health, Safety, Environment and Quality (HSEQ) Audits.”

We classify critical incidents during the transportation of our products as transport incidents. These include accidents that cause personal injury, significant damage to property, environmental impact through the release of substances or leakage of hazardous materials. We record transport incidents ­using defined criteria. Assessment is based on the leaked load, graded according to the volume and dangerous goods class, personal injury and blocked transportation routes. We take into account both our own chemical transports and those we commission and pay third parties to perform on our behalf.

In total, well over one million transport movements took place in 2013. Despite extensive safety precautions and training activities, it is unfortunately impossible to prevent transport incidents from occurring altogether. We carefully analyze and evaluate all incidents so that adequate steps can be taken to prevent a recurrence. The number of transport incidents in the reporting period rose from six to 11. All incidents occurred on the road or at sea.

Transport Incidents by Means of Transport [Table 3.11.2]
20092010201120122013
Road86668
Rail21100
Inland waterways0 1000
Sea0 0003
Air0 0000
Pipeline0 0000
Total10 87611

A detailed overview of the transport incidents can be found in Chapter 12.6 “Environmental Incidents.”

Last updated: February 28, 2014  Copyright © Bayer AG
http://www.annualreport2013.bayer.com