One of the leading cement producers in the world, Titan Cement Company S.A., began building a new cement manufacturing line in Beni Suef, Egypt in 2007. Senior management was adamant that the €150 million investment be built without any safety incidents. This was going to be particularly difficult since there was no local staff to supervise the project on site. In addition, the project relied on contractors who sub-contracted the work to local Egyptian firms — which meant over 1,300 people would be on site with little to no experience working to high safety standards.
Faced with these challenges, Titan brought in Dupont Sustainable Solutions (DSS) to strengthen safety protocols and bridge cultural gaps. DSS approached the project in 4 stages, through a “Plan-Do-Check-Act” cycle. First, in the Plan phase, DSS worked to align all parties with Titan safety performance expectations. Afterward, DSS set up a contractor management training system to create requirements for common construction high hazard activities, like inspections and a Permit to Work system. DuPont then provided monthly on-site observation and systematic field audits, technical advice, and customized safety training events in the ‘Check’ phase. Finally, A pre-start up review was conducted to ensure all necessary safety checks were performed.
As a result, construction was completed on time with Zero Lost Time Incidents in 6.5 million man hours. Dupont Sustainable Solutions kept tight control of contractor and sub-contractors through clear communication and leadership. The successful project lead to lasting change to safety habits and procedures within Titan.