What Chemical and Energy Leaders in Texas Can Teach Us About Zero-Incident Operations
Kuraray, Ascend, Kaneka, and Phillips 66—four chemical and energy giants operating in our Houston backyard. They manufacture everything from specialty chemicals to petroleum products, navigating hazardous materials, extreme temperatures, and heavy machinery daily. Yet, despite the risks, they share one goal: zero incidents.
How do they make safety second nature? Here’s what we can learn from the best in the chemicals, materials, and energy industries.
Keep talking about safety
Toolbox talks, shift handovers, and pre-job safety meetings are great, but they’re not the only moments for safety discussions. Every workplace conversation can be about safety. That doesn’t mean safety should be forced into every discussion but it should be a natural part of daily operations.
The best safety messages are clear and concise, and keep your audience in mind. A conversation with an engineer won’t look the same as one with a contractor or an operator on the floor.
And communication is as much about listening as it is about talking. Two people can walk away from the same conversation with completely different takeaways. That’s why feedback matters. Leaders need to create space for questions and pay attention to non-verbal cues—because sometimes silence says more than words.
Make sure everyone can recognize hazards
To move to zero-incident operations, you need to spot risks before they turn into accidents. That starts with a structured approach to hazard recognition, like the Hazard Recognition Plus method, which focuses on five key thought processes:
- What’s the job? Define the task at hand.
- What energy is involved? Identify potential sources of danger.
- Where is that energy going? Understand movement and impact.
- How will it be managed? Determine control measures.
- What are the stop-the-job triggers? Know when to hit pause.
Beyond that, risk reduction strategies fall into three categories: remove the hazards altogether, or contain them, and when neither is possible, focus on personal protection.
The most effective companies don’t just train employees on hazard recognition once and assume it’ll stick. They keep hazard recognition top of mind through awareness messages, posters, and real-life examples.
Build a “speak up” culture
A strong safety culture doesn’t just happen—it’s built on trust, accountability, and follow-through. Asking employees to speak up is a good start, but what really matters is what happens next.
Every near miss, close call, or concern must be taken seriously. Leaders should be out on the plant floor, reviewing incidents, and sharing what they find right away. When employees see their input leads to real action, they’ll keep speaking up—and that’s how a real safety culture takes shape.
Don’t just tick the boxes
When it comes to safety, it’s easy to mistake activity for progress. Filling out paperwork, completing an audit, or checking boxes on a list might feel like getting things done—but is it making you safe? In the words of Ben Mitchell, North America Director of HSSE at Kaneka, “It just means that you are a compliance scholar—you’re making sure your paperwork looks good.”
The same goes for training. It’s not just about sitting through a course, it’s about making the lessons stick. Too often, employees leave a session feeling motivated, but once they’re back on the job, nothing really changes. The lessons fade, and old habits take over.
The best companies don’t let that happen. They reinforce training through mentorship, hands-on practice, and regular follow-ups.
Using EHSQ software to support zero-incident goals
Zero-incident operations aren’t just about compliance; they’re about making safety second nature. To do that, you need a tool that turns safety plans into action.
Software solutions like TenForce help by providing:
- Centralized risk management, where you can track all hazards and resolutions in one place.
- Real-time incident tracking, so you can identify and address safety gaps before they escalate.
- Standardized safety processes, to reduce human error.
- Automated workflows, so that the right people are notified, at the right time, to keep tasks from slipping through the cracks.
- Hazard recognition tools, to help employees spot risks faster and act.
- Audit and compliance tracking, to make sure safety measures are effective, not just checked off.
- Training reinforcement, to keep safety top of mind with refreshers and knowledge checks.
Unilin’s Journey: Implementing a Zero-Harm Policy with TenForce
Since 2019, Unilin, a global flooring and materials manufacturer, has used TenForce’s EHSQ software to support their zero-harm policy. They use TenForce to keep safety processes clear, consistent, and proactive, including:
- Incident Management – Logs accidents and hazards, tracks follow-ups on corrective actions, and connects with PowerBI for real-time safety insights.
- Zero-Harm Tools – Helps manage safety meetings, job safety briefings, and life-saving rule checks, with a mobile app for quick risk reviews in the field.
- Work Permits – Organizes work planning, risk assessments, and permit approvals, ensuring last-minute risk checks and fire safety measures are in place.
The result? A stronger safety culture and fewer risks on the shop floor.
Want to see how Unilin turned its safety commitment into measurable results? Read the full case study:
To hear exactly how these industry leaders prioritize safety, check out the original article by Jeremy Osterberger, President and COO of BIC Alliance.
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