From zero to hero. A case study of industrial injury reduction: New Zealand Aluminium Smelters Limited

Abstract

There is a need to pursue more evidence to support the zero accident vision (ZAV). New Zealand Aluminium Smelters Limited (NZAS) has been operating under a ZAV for more than two decades and now consistently has fewer than ten lost-time injuries (LTI) per annum. While the ZAV has not been fully realised, NZAS is now one of the safest heavy industrial worksites in the world. This mixed method case study substantiates the significant reduction in LTIs and describes the interventions used to achieve the improvement. The interventions are rated using a hazard intervention effectiveness matrix and by contextualising their apparent efficacy within the available literature. The NZAS ZAV achievement is further analysed using goal theory. The study concludes by attributing NZAS’ relative success to an assiduous application of hierarchy of control methodology with a particularly strong ergonomic focus.