BBS Case Study

Successful Implementation of Behavior-Based Safety (BBS) in the Steel Industry

In the complex and high-risk environment of the steel industry, safety is a critical concern. Our client, a leading steel manufacturer, sought to enhance workplace safety through the implementation of a Behavior-Based Safety (BBS) program. With over 5,000 employees working across multiple sites, the primary goal was to reduce incident rates and create a sustainable safety culture by targeting unsafe behaviors.

This case study outlines the structured approach taken to implement BBS over 2.5 years. It provides a detailed account of each phase, highlights the data-driven decisions made, and showcases the impact of the project using statistical insights.

Client Industry

Steel Manufacturing

Project Duration

2.5 Years

Consultant Involved

6 (Total Consultant)

BBS Consulting Project Phases and Approach

Phase 1

Gap Assessment First 3 months

Phase 2

Framing strategy Months 4 - 8

Phase 3

Training & Educate Months 9 - 14

Phase 4

Implementation Months 15 - 22 

Phase 5

Review & Improve Months 23 - 30

Phase 6

Data Analytics Ongoing

Phase 1 - Gap Assessment (First 3 months)

Before implementing any safety interventions, we conducted a thorough  gap analysis . This step involved:

  • Site Visits:  Detailed inspections across multiple steel plants.
  • Behavioral Observations:  Conducting over 1,000 behavior-based observations.
  • Incident Data Review:  Historical data analysis of past safety incidents and near misses.
  • Employee Interviews:  Engaging with employees at all levels to understand perceptions of safety practices.
                                                            Diagnostic Tool
Odoo • Text and Image

Phase 1 - Key Findings

Safety Procedure

Lack of consistent safety practices across different shifts.

Safety Culture

A reactive rather than proactive approach to handling safety incidents.

Employee Engagement

Minimal employee engagement in safety improvement initiatives.

Statistical Highlight: Phase 1


70% of the safety incidents were attributed to behavioral causes rather than equipment failures.

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Phase 2Framing the Strategy (Months 4-8)

Post-gap assessment, we designed a  customized BBS strategy  tailored to the client’s operations. Key components included:

  • Leadership Engagement:  Ensuring commitment from top management.
  • BBS Steering Committee Formation:  Cross-functional teams to drive the BBS agenda.
  • Action Plan Development:  Specific goals to reduce behavioral risks in high-incident areas.


C-ZAP Model

Data Driven Decision : Phase 2


The focus was placed on high-incident zones like the furnace and rolling mill, where 80% of unsafe behaviors were reported.

Phase 3Training & Communication (Months 9-14)

For successful BBS implementation, training was essential. This phase included:

  • BBS Workshops for Leaders:  Focused on leadership’s role in driving behavioral change.
  • On-the-Job Training:  Frontline workers were trained to identify unsafe behaviors.
  • Safety Communication Channels:  Digital tools and dashboards were set up for reporting and monitoring behaviors in real-time.


BBS Training

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Phase 3 - Key Results

BBS Training

Over 2,000 employees were trained in behavioral observation.

BBS App

A 45% increase in safety reporting after the introduction of new communication tools.

Employee Engagement

63% participation increase in safety activities by frontline workers

Statistical Highlight: Phase 3


90% of trained employees reported feeling more confident in identifying unsafe behaviors.

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Phase 4 - Handholding & Implementation Support (Months 15-22)

During this phase, we provided  on-site support  to ensure the smooth execution of the BBS program:

  • On-site Consultants:  Six consultants were deployed to guide the BBS process.
  • Mentorship Programs:  Key employees were identified as BBS champions, who were mentored to sustain the program independently.
  • Safety Observations:  50,000 safety observations were conducted across different shifts, with corrective actions implemented.

Data Driven Decision : Phase 4


Shift timings were restructured based on safety data, resulting in a 30% reduction in incidents during the night shift.

Phase 5 - Review Meetings & Continuous Improvement (Months 23-30)

Regular review meetings were integral to tracking the progress of the BBS program:

  • Monthly Review Sessions:  Discussing observation data, incident reports, and improvements.
  • Behavioral Trends Analysis:  Using analytics tools to assess patterns in unsafe behaviors.
  • Employee Feedback Surveys:  Regular surveys to gauge the program’s effectiveness.
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Phase 5 - Key Impact

Incident Rate

A 60% reduction in overall safety incidents at the workplace.

Compliance Rate

Consistent 98% compliance with safety protocols across all departments.

Behaviour Change 

73% Increase in safe behaviour at the workplace across all department 

Statistical Highlight: Phase 5


Post-BBS implementation, near-miss reporting increased by 200%, indicating heightened awareness.

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Phase 6 - Data Analytics & Tools (Ongoing)

A key aspect of the project’s success was the integration of a  data analytics tool  to provide real-time insights:

  • Custom Dashboards:  These allowed supervisors to track safety behaviors and incidents in real-time.
  • Predictive Analytics:  The system identified high-risk behaviors before they led to incidents.
  • Data-Driven Decisions:  Decisions such as increasing safety audits during peak production times were made based on the data analytics provided.

Data Driven Decision : Phase 6


Predictive analytics helped avoid potential incidents by identifying behavior patterns linked to equipment misuse.

BBS Consulting Project Outcome & Results

The BBS implementation yielded significant improvements in the client’s safety culture. Below are the key metrics which demonstrating the project success.

Safety Incident Reduction

60% decrease in safety incidents across all plants.

Near-Miss Reporting

200% increase in reporting, highlighting proactive safety measures.

Behavioral Compliance

98% compliance rate with new safety protocols.

The successful implementation of the Behavior-Based Safety (BBS) program within the steel industry led to substantial improvements in safety practices, a significant reduction in incidents, and an empowered workforce. The integration of data-driven tools enabled real-time monitoring and long-term sustainability of the program.

The project serves as a benchmark for industries seeking to improve their safety standards through behavioral interventions. 

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