Introduction
At DECO Group, safety isn’t just a policy—it’s woven into our DNA. Faced with the immense scale and complexity of the Hassyan 180 MIGD SWRO IWP Project, we adopted the Swiss Cheese Model to guard against incidents at every turn. By stacking multiple, independent layers of protection—and continuously strengthening them—we achieved 6 million safe man hours without a single Lost-Time Incident (LTI). This performance earned us the Number 1 Compliant and Best Contractor accolade at Hassyan Water A and reaffirmed our zero-compromise stance on HSE excellence.
The Origin and Power of the Swiss Cheese Model
Developed by psychologist James Reason, the Swiss Cheese Model illustrates how complex systems fail only when individual defenses all align to let a hazard slip through “holes” in each layer. In practice, no single barrier is infallible—but multiple defenses, carefully maintained and monitored, drastically reduce risk.
- Each “slice” represents a different safety control: organizational policies, training, behavior checks, engineering measures, and PPE.
- The “holes” in each slice—human error, system gaps, environmental factors—are inherently unpredictable.
- By layering controls and constantly auditing them, the odds of all holes lining up drop exponentially.
DECO harnessed this model to transform theoretical safety into tangible, day-to-day protection.
1. Organizational & Management Controls
The top slice sets the tone for every other layer. At Hassyan Water A, DECO’s leadership:
- Exceeded UAE Regulations: We benchmarked against ISO 45001 and local DEWA standards, then went further—introducing bespoke HSE KPIs for real-time performance tracking.
- Embedded Safety in Strategy: Quarterly HSE reviews with the project steering committee ensured earmarked budgets for training, incident investigations, and technology upgrades.
- Transparent Leadership Rounds: Senior executives joined weekly site walks, personally recognizing safe practices and coaching teams on near-miss prevention.
These initiatives cultivated a culture where safety decisions were integrated into every business discussion, from bid evaluation to close-out.
2. Preconditions for Safe Work
Before a single cable was pulled, DECO cemented a bedrock of readiness:
- Rigorous Competence Assessments: Over 1,200 site personnel completed role-specific HSE certifications, including SWRO process hazards and confined-space protocols.
- Safety Mindset Campaigns: “Pause, Plan, Perform” posters and toolbox challenges reinforced individual responsibility. We tracked positive safety observations, rewarding teams with monthly “Safety Champions” recognition.
- Ergonomic & Environmental Checks: Work areas featured anti-fatigue mats, adjustable lighting, and climate-controlled rest zones. Noise surveys and dust monitors ran 24/7, with real-time alerts to supervisors.
By eliminating readiness gaps, DECO minimized conditions that typically lead to unsafe acts.
3. Addressing Unsafe Acts
Even with strong foundations, people sometimes stray from protocols. DECO tackled this by:
- Behavioral Safety Observations: Over 3,500 peer-to-peer observations were conducted, uncovering inadvertent shortcuts—like skipping lockout/tagout or improper ladder use—before they became incidents.
- Immediate Corrective Coaching: Supervisors applied a “Stop-Proceed-Discuss” approach: halt unsafe tasks, realign practices, and debrief on prevention.
- Incentivized Near-Miss Reporting: Near-misses rose by 30% year-over-year, demonstrating growing vigilance and trust in the system. Reporting became synonymous with proactive care, not blame.
This relentless focus on human factors kept unsafe behaviors from cascading into accidents.
4. Engineering & Administrative Defenses
The final slice involved fail-safe systems and strict governance:
- Machine Guards & Interlocks: Custom-designed barriers on high-pressure pumps automatically cut power if accessed during operation.
- Digital Permit-to-Work: A cloud-based system enforced task approvals, hazard checks, and sign-offs—eliminating paperwork errors and ensuring traceability.
- PPE Innovations: We piloted smart helmets with integrated gas detection and location tracking, boosting first-responder readiness.
Routine inspections—over 1,000 to date—confirmed these controls never lapsed, providing peace of mind even under challenging marine-coastal conditions.
Measurable Outcomes & Continuous Improvement
Our layered approach didn’t just prevent incidents—it delivered measurable business value:
| Metric | Baseline (2023) | After 6 Million Man-Hours | Improvement |
|---|---|---|---|
| Lost-Time Injury Frequency Rate | 0.12 LTI/200,000h | 0 LTI | 100% reduction |
| Near-Miss Reports | 2,800/year | 3,650/year | +30% |
| HSE Audit Findings (High-Risk Gaps) | 18 | 2 | –89% |
| Training Compliance | 95% | 100% | +5 pp |
These results empowered us to refine procedures, optimize resource allocation, and share best practices across DECO’s global portfolio.
Sustaining the Layers: DECO’s Next Frontier
To keep those “holes” from ever lining up, DECO is deploying:
- AI-Driven HSE Analytics: Early-warning dashboards that flag risk trends before they materialize.
- Virtual Reality Training: Immersive SWRO scenarios to reinforce hazard recognition in a controlled environment.
- Cross-Project Learning Hubs: Monthly “Safety Exchanges” where teams from different sites present lessons learned.
By adopting next-gen tools and collaborative platforms, we’re making sure our defenses not only withstand challenges but adapt and grow stronger with each one.
Closing Thoughts
The Swiss Cheese Model teaches us that accident prevention isn’t a single silver bullet—it’s the sum of steadfast leadership, prepared people, disciplined behaviors, and engineered safeguards. DECO’s success at Hassyan 180 MIGD SWRO IWP demonstrates that when these layers remain strong and distinct, achieving zero harm becomes a realistic goal.
Safety is everybody’s responsibility. Let’s each protect our slice of the cheese—so the holes never align, and we continue to set the standard for excellence in HSE.
