Safety

Behavior-Based Safety through a Manufacturing Lens

When effectively implemented, Behavior-Based Safety Programs (BBSP) are crucial tools for reducing unsafe behaviors, with key factors like the Safety Pyramid, work environment, and the use of checklists and evaluation forms playing essential roles in their successful application. These elements collectively foster a proactive safety culture, ensuring long-term effectiveness in reducing workplace hazards and enhancing overall safety performance.

Background of BBS

The history of behavior-based safety is traced back to 1931, when Herbert William Heinrich’s examination of data collected while working for the inspection division of the Travelers Insurance Co. established a foundational basis for contemporary safety management principles. He outlines his analysis and safety pyramid model in his book, Industrial Accident Prevention: A Scientific Approach (Dunlap et al.). While Heinrich established the groundwork for BBS, it was Frank Bird that further expanded the pyramid model and proposed the modern accident causal chain theory dubbed “Bird’s Triangle". His theory links “the number of near misses and the number of significant casualties, claiming that human intervention could predict and prevent most accidents” (OSHA.com 2). However, it wasn’t until 1979 that Gene Earnest and Jim Palmer, two safety professionals at Proctor & Gamble, coined the term “behavior-based safety” when developing methodologies drawn from behavioral sciences (Krause). This historical evolution underscores the growing understanding of safety management, emphasizing the critical role of human behavior in accident prevention and shaping the framework for modern BBS strategies.

Behavior-Based Safety Explained

Behavior-based safety (BBS) as defined by OSHA, is a “proactive approach to increasing workplace safety by observing individual behavior, analyzing the consequences, and reinforcing desired safety behaviors” (OSHA.com).  When applying BBS to any work environment, it is critical to acknowledge that unfavorable work environments can force people to decide between working properly and taking shortcuts, rather than thinking of ways to promote safe behavior. Behavior can be understood as any action or vocal expression; in the field of psychology, it refers to an individual's reactions or responses to both internal and external stimuli (Choudhry, 2014). The foundation of any BBS program is the belief that safety within an organization as a whole can be improved by altering individual behaviors. 

A group of researchers at Georgia Institute of Technology explain that “BBS programs are strategically devised to engage the workforce in the implementation and utilization of their own safety initiatives; the crux of this approach is centered around the fundamental practice of workers observing their peers and providing feedback on safe and at-risk behaviors." The objective of BBS programs is to ‘foster a culture transformation inside a company’ that permits employees to intervene at any moment to prevent harmful work practices (Yang et al.). By prioritizing active involvement and peer-to-peer feedback, BBS programs not only address immediate safety concerns but also lay the groundwork for sustained behavioral change and long-term organizational safety culture.

The Pyramid 

Proper implementation of a BBS program starts with Bird’s Triangle, also known as the Safety Triangle or Accident/Incident Triangle. Bird’s Triangle outlines the relationship between serious and minor accidents as well as near misses. The theory suggests that if the frequency of unsafe acts, near misses, and minor accidents decreases, the number of serious accidents will decrease accordingly (OSHA.com 2). Indicators of safety risk can be better identified when companies and workers are proactive about safety measures within each level of the triangle, thus improving worker safety. For example, placing hazard signs in a construction zone is a proactive way to prevent unsafe acts and near misses. Understanding how to identify and prevent unsafe acts, near misses, and minor accidents is crucial for an accident-free work site, as there will be a decrease in serious accidents and fatalities.

Example of Bird’s Triangle

Bird’s safety triangle does not come without criticism or concerns. Bird's blanket ratio does not apply uniformly across all industries, indicating that the proportion of near misses to serious accidents may vary significantly between different sectors. Another concern is with the notion of primarily focusing on minor accidents and near misses. By focusing on those two factors alone, there is diminished attention to actions that cause major accidents. There is also the possibility that excessive blame can be placed on the individual or group of workers for any incident failure (Eric Marsden). These critiques underscore the necessity for a more nuanced approach to safety management that considers the distinct attributes of different industries and promotes a balanced view of both human and systemic elements in accident prevention.

There may be limitations to Bird’s Triangle, but overcoming the limitations is possible. For example, rather than immediately blame the worker’s behaviors for any incident failure, first try and see if there is a flawed process or poor design that possibly caused failures, then consider any behavioral mistakes. Understanding that Bird’s Triangle can be used as a tool within BBS programs rather than as the solution for safety risk within the workplace is key to proper implementation of BBS programs.

The Work Environment and Safety Behaviors 

A poor work environment can significantly contribute to workers exhibiting poor safety behaviors. Factors such as cluttered workstations, inadequate maintenance of job sites, and consistently high-stress conditions can all undermine safety and lead to the adoption of unsafe practices and behaviors. Yang et al., the group of researchers from Georgia, provide examples of commonly observed at-risk behaviors in a construction electrical contracting company—  some behaviors being: 

◦ Standing or working in the “Line of Fire":  linked to a disorganized or congested workspace where the risk of being in a hazardous zone is increased

◦ Rushing/frustration: observed in 24 different tasks. This behavior could be a direct result of tight deadlines, high workload, or other stressors in the work environment.

◦ Fatigue: Exacerbated by long working hours, inadequate rest, and demanding work conditions.

These examples, particularly "rushing/frustration" and "fatigue," directly suggest that aspects of the work environment or work organization can lead to workers exhibiting unsafe behaviors. 

After the implementation of a BBS program, more than 65% of respondents reported that the safety climate has improved in all criteria, reports of unsafe behaviors ranged from ‘Proactive’ and ‘Exemplary’.  (Yang et al.). This illustrates the substantial influence that tackling environmental and organizational elements through BBS Programs may exert on improving safety behaviors and cultivating a more supportive workplace culture.

Checklists and Evaluation Forms 

A behavior-based safety program is characterized by four fundamental elements: observation, feedback, goals, and checklists. OSHA describes a successful BBSP as including the following: 

• Behavior-Based Safety Goals: A Behavior-Based Safety (BBS) program should begin with the establishment of clear, structured goals, preferably following the SMART criteria (specific, measurable, achievable, relevant, and time-bound). Well-defined goals help to narrow the focus of the program and provide direction for action, while also establishing a timeline for achievement. Examples of such goals include reducing unsafe behaviors, increasing the correct use of personal protective equipment (PPE), and decreasing the rates of recordable injuries.

• Behavior-Based Safety Checklists: Following the formulation of goals, checklists of observable behaviors should be compiled. Checklists should be tailored to the specific workplace, taking into account its unique protocols, equipment, and relevant OSHA standards. The selected behaviors must be observable, within the control of the employee, and framed in a positive manner, focusing on actions that should be performed rather than avoided.

• Behavior-Based Safety Observations: Employees designated as observers should receive training in identifying both safe and unsafe behaviors and providing constructive feedback. It is essential to establish clear guidelines for the observation process, including proper recording procedures. Observations should be scheduled in advance to mitigate any negative perceptions, ensuring that typical behaviors are assessed over an adequate period of time. Examples of behaviors to observe include improper handling of hazardous substances without gloves, incorrect use of safety glasses, or setting up a ladder on uneven ground.

• Behavior-Based Safety Feedback: Feedback plays a vital role in the success of BBS programs. While corrective feedback is necessary, positive feedback is crucial for reinforcing safe behaviors and promoting a culture of safety. Positive feedback highlights desired behaviors, brings attention to them, and strengthens the overall safety culture. All feedback should be directed at specific individuals, focus on particular behaviors rather than personal traits, and emphasize the importance of the safe behavior being reinforced.

 By establishing clear, measurable goals, developing detailed checklists, training observers to identify safe and unsafe behaviors, and providing timely and constructive feedback, organizations can foster a culture of safety that encourages proactive involvement from all employees. When implemented effectively, these fundamental elements not only reduce the likelihood of accidents and injuries but also promote lasting behavioral change, ultimately enhancing the overall safety performance within the organization. 

Concluding Thoughts

Behavior-Based Safety Programs (BBSP) offer a comprehensive framework for improving workplace safety by focusing on individual behaviors and promoting a proactive safety culture. Through the integration of historical theories such as Bird’s Triangle, careful consideration of the work environment, and the use of structured elements like goals, checklists, and feedback mechanisms, BBS programs provide organizations with a systematic approach to reducing unsafe behaviors and enhancing safety outcomes. The implementation of BBS strategies not only addresses immediate safety concerns but also fosters long-term behavioral change that contributes to a sustained culture of safety. Ultimately, a well-structured BBS program is an essential tool for organizations seeking to improve both safety performance and operational efficiency, ensuring that employees work in an environment that prioritizes health, safety, and well-being.

Summary

• The foundation of BBS is the belief that altering individual behaviors can significantly improve overall safety within an organization. Key factors for successful implementation include the Safety Pyramid, work environment, and the use of checklists and evaluation forms.

• The roots of behavior-based safety trace back to Herbert William Heinrich in 1931, who established the foundational safety pyramid model.

• Frank Bird expanded the safety pyramid into the "accident causal chain" or "Bird’s Triangle," linking near misses to serious accidents.

• BBS is defined by OSHA as a proactive approach to improving workplace safety by observing behaviors, analyzing consequences, and reinforcing safe practices.

• The goal of BBS programs is to foster a culture transformation where employees actively participate in safety initiatives and intervene to prevent harmful work practices.

• Bird’s Triangle outlines the relationship between unsafe acts, near misses, and accidents, suggesting that reducing unsafe acts and near misses will reduce serious accidents.

• Criticisms of Bird’s Triangle include its inconsistent application across industries and the risk of focusing too heavily on minor accidents and near misses at the expense of more severe issues.

• Essential Elements of BBS Programs:

• Safety Goals: Establish clear, structured goals, preferably using the SMART criteria, to guide the program’s focus and direction.

• Checklists: Develop observable, positive behaviors tailored to the specific workplace and OSHA standards.

• Observations: Train observers to identify and provide feedback on safe and unsafe behaviors, using scheduled observations for a clear understanding of typical behavior patterns.

• Feedback: Provide timely, constructive feedback, with a focus on positive reinforcement to promote safe behaviors and strengthen the safety culture.

• Well-implemented BBS programs help create a lasting culture of safety that improves both safety performance and operational efficiency, ensuring employees work in a safe and healthy environment.