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The Safe Summit: Everest Lessons to Elevate Safety and Reach New Heights with Alan Mallory

The Safe Summit: Everest Lessons to Elevate Safety and Reach New Heights

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In this inspiring and unforgettable episode, Alan Mallory shares his remarkable journey to the summit of Mount Everest, unpacking countless connections to workplace safety and powerful leadership lessons gained with every step toward the peak. Drawing from his record-setting ascent, Alan reveals how to confront blind spots, overcome complacency, and navigate adversity to safely reach the summit of the world’s highest mountain with his team. He emphasizes the importance of increasing awareness, embracing continuous learning, and building strong team relationships to help keep ourselves and others safe. Don’t miss this gripping conversation packed with real Everest lessons to elevate safety and help you reach new heights. Tune in now!

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Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and well-being of their people first. Great companies ubiquitously have safe, yet productive operations. For those companies, safety is an investment, not a cost for the C-suite. It’s a real topic of daily focus. This is the Safety Guru with your host, Eric Michrowski, a globally recognized ops and safety guru, public speaker and author. Are you ready to leave a safety legacy? Your legacy success story begins now.

Hi, and welcome to the Safety Guru. Very excited to have with me, Alan Mallory. He’s an Everest Mountain climber, an engineer by trade with also a master’s in psychology. I’m looking forward to a very exciting conversation today. Allan, maybe tell us a little bit about your story and how you got to Mount Everest.

Sure. Well, it’s a pleasure to be on the show, Eric. I’m an engineer by trade. I have a technical background, but I grew up in a very adventurous family, and my father really got us into a lot of outdoor activities and adventure activities from a young age. We did a lot of whitewater canoe trips and winter camping and that thing. He actually got my siblings and I into mountaineering as well. When each of us were 19, he took us to climb one of the seven summits, the highest mountains on each of the seven continents. In my case, it was McKinley here, Denali. That was my introduction to it, and it was no cakewalk. That was a dangerous, difficult mountain as well. It takes two weeks to climb. And then this would have been about 2006 when we first started talking about Everest. And my father originally started those discussions, and the more I think, each of us looked into it, this is my brother’s sister and I, it became, what do I say, morphed into a personal dream, that thing. I like putting myself or doing things that prove to myself that I can. That’s the intrinsic motivation is all about.

And so that’s how the idea of Climbing Everest came together. We were two years in the planning beforehand. And then, of course, once the actual climbing begins, you’re climbing for two months straight. And it was a harrowing, exciting, yet crazy journey.

Tell me about some of the lessons you talk a lot about that and the connections to safety. Tell me a little bit about your experience reaching new heights, but also in terms of how it connects to safety and leading safety.

Sure. Well, it’s a relatively dangerous expedition. I mean, people die every year. There are three people died at camp four while we were there. And that’s the typical, even just on the south side. And some years are much worse. Now, a lot of the deaths, or I would say the majority of the deaths are human error when you look back. There have been natural disasters, and that’s when we’re doing risk management, you have to look at, well, what can you avoid? Then what can you transfer in terms of risk? We use an outfitter to do that. Replacing the tents and things that get destroyed, replenishing our food surprise, that thing. What can you mitigate? And then what’s left is what you’re accepting if you want to take on something like this. And these are those unknowns, like avalanches that can happen at any point. But having said that, I mean, most of the deaths are human error. Climbers that don’t take the planning seriously. They try to deviate too far from their schedule because they have that dream to reach the summit. And so when you’re functioning on a third mental capacity because of the of oxygen to your brain, you basically get what is an amygdala hijack, where your emotional side of you suppresses the rational to some degree, and so you make poor decisions. 

Sure. And we made mistakes as well. But I think the fact that the four of us there, we were able to run things by each other. And so, the risk management is a huge thing for Everest mountaineering. And it was particularly important in our expedition because we were an unguided team, it was even hard to find an outfitter that would support us because they didn’t know who we were and they’re trying to run their business.

There’s a bigger risk for them. Sure. They don’t know who you are.

We had a bit of a hybrid where we needed the logistical support from one of these larger outfitting groups, but we wanted to be in control when we climbed and when we didn’t and making our own decisions. We were able to find a few that were open to the negotiation, and that’s eventually what came to. And part of it was they wanted to have two of their Sherpas. They were local Nepalese climbers with us. So really, there were six of us. But they weren’t… We weren’t part of… Because they also had more of a structured group that was working together. And then there was us, which were our own team within this larger umbrella. And so why it was so important to us is because in a typical expedition on Mount Everest, you are transferring They’re offering all of the risk over to a guide because they’re making the decisions of when you climb and when you don’t and all of that. If they make a mistake, though, it’s your life. We wanted to be in control of that. That’s why it mattered so much in our case to understand the risks and so on, because we had to do the scheduling ourselves and figure out when we climbed and when we didn’t, and when we might be pushing too far into the altitude and risking getting cerebral or pulmonary edema, for example.

Anyway, so we had two years to try to research and figure that out. But it’s also very much, what would I call it, an agile project when you’re there. You’re having to learn from Every time you make a push into the altitude. But if you stay there, you run the onset of getting that acute mountain sickness, which leads to edema. So, you come back down and you’re informing your next iteration or next push into altitude by what you’ve learned. And so that’s a key aspect in safety, right? 

Yeah, absolutely. This continuous learning that you’re trying to build into your practices.

Sure. And from my engineering background, I’ve seen how that can really be problematic when people are so reliant, let’s say, on procedures and processes that they turn off the learning element of their mind, blindly follow the procedures. There’s obviously a place for procedures, so you have consistency, but you also have to be aware. That awareness in mountaineering is particularly important because it allows you to make those adjustments that are needed in order to be able to survive in such a volatile environment. Everything is just changing so quickly.

It’s interesting because when you talk about different guides, I’ve used many times a case study of a guide or even two guides that had gone many years ago up, and one of them in terms of the decision making, how they were trying to push to get to the summit and weren’t really looking at the skills and the capabilities on their team. It resulted in multiple fatalities, pretty serious outcomes. Flip side, though, is you have somebody who’s done it before, who’s bringing essentially the lessons learned and a lot of the safety rules are based on learnings of others who’ve gone some way. How did you compensate for some of those?

Well, I think that was the… How we compensated. I mean, I would say, why did we… I guess the question would be, why did we feel like we were competent enough to take on something like that? Because you make a good point. Someone who’s there all the time would certainly have their own… There’s a major benefit in that. We were combining the knowledge and skills and everything we’d learned on these other expeditions because each of us had… It’s not like we were going into this green and we didn’t have a mountaineering experience, but we didn’t have experience in the high altitude and the Himalayas in particular. That’s where I would say the knowledge and experience from the outfitting group that we were part of. We tried to, especially the lead of that in the years up before the climb, we tried to, what I say, extract as much information from his mind and experience as possible so that we could use that to inform our own decisions. You’d call that bringing in a subject matter expert when making decisions. Then also having those two Sherpas was at first it wasn’t clear that benefit, detriment, because it’s different culture, different language, a lot of different differences.

And now you’re trying to, in a relatively short time, build relationships that need to be deep enough that you’re putting your lives in each other’s care. Between my siblings and my father and I, we had that bond already established. But with our Sherpas, it wasn’t so much the case. But early on, we tried to break down those barriers between us and them. I would say how we did that was… I saw a lot of the other climbers there. They don’t particularly They treat the Sherpas very well. A lot of climbers tend to be people who’ve reached the upper echelon of whatever sphere they’re in, businesspeople, that thing. Everest is almost hardwired in us to reach the top of whatever endeavor we’re in. And so, they’re used to pretty good service. I don’t know. I just saw that treating the servants, that thing. And we tried not to do that. We tried to… When What we were involved in, even at some of the… At one point, we had to go down below base camp to one of the little villages, and we were playing pool and cards and telling jokes. And it was like the six of us.

We really built a good relationship. We tried not to have it be us and them. Because they want to reach the summit as much as we do. If you’re a Sherpa and your resume doesn’t say summit, you’re not nearly as marketable. It’s critical. And many of, I would say most have I’ve never been to the summit. Because there’s a lot of Sherpas working behind the scenes and only one or two would be those high altars.

I see. They go all the way to the top.

Yeah. And the success ratio when we were there was only 29% historically. So, 70 % of clients are turning back. And so that means if you’re a Sherpa, you only have the chance of making it one every three years. And so that’s that relationship with them. And so, they weren’t really involved in… We would run things by them, is how I would say it, and really respect. They’ve been up there before. I can think of a few times when they really did have a really good insight. When we were on their way back down from the summit, we’d been climbing for about 30 hours straight right through the night, and we’re delirious. We’ve got the altitude problems. We just gotten down the Hillary Step section, which is a rocky, pretty treacherous area. And there was a little plateau, and I was just so exhausted and tired. And I thought, well, I’m just going to flop over on my side here for a second and just rest for a few seconds or maybe a minute. It seemed at the time like the logical thing to do. And I can remember Zangpo, one of our Sherpas. As soon as I did that, almost immediately, he was there.

He’s, I don’t recommend this. I don’t recommend this. And he was right, and I knew it was right. If you ever seen any of the Everest movies, everyone does that. They just end up there forever because your body just shuts down. But anyway, I just wanted. So, yeah, immediately we just forced ourselves to our feet and just kept going. If you keep moving, you stay alive. Or that’s the hope anyway. The percentage of summiteer’s that perish is actually relatively high. Overall, I think it was about two and a half % fatality.

And it’s much, much lower than it used to be. It’s gone much, much safer.

Yeah. And maybe that was, I think, when we were doing it. It’s probably even lower than that now. Yeah. So, it’s not… But anyway, that still makes it the most dangerous adventure activity when you compare it to scuba diving and sky diving and all of that stuff.

Some of the themes you talk about when you’re building rapport with Sherpa is what comes to mind is also creating psychological safety because you need a brother, sister, keeper. Somebody is looking out for you. And so really investing in making sure you have that relationship because we know that there’s been some examples. If I go to aviation where captain is flying the plane, they’re running out of fuel, first officer or a flight engineer realizes that there’s no fuel, doesn’t feel comfortable speaking up in that environment. Whereas we know this is not a good outcome. If you have no more fuel, you need to do something. That psychological safety becomes so key if you want somebody to speak up at those key moments.

Yeah, no, and I can remember that example from aviation. Yeah, exactly. So, keep the communication. And there were some challenges there because they could speak English, but it was broken English. But a lot of times we’re using nonverbal cues to communicate well and rely a lot on that. And yeah, so I mean, we just became friends over the two-month period more than anything. And that was a major advantage. When you have friends, you look out, you do things for them and work together to make it a reality. Because for almost the entire two months, one or more of us was so sick or weak or, let’s say, cognitively not there, that the others had to step in and pick up the slack. So that was key.

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How do you manage this risk assessment on an agile basis? Because what you’re describing is you’re going to new areas that you’ve never explored. It parallels from a mission standpoint. If you’re thinking about a lot of non-routine tasks and functions, there’s similar parallels where you’re going to an area that’s uncharted. Maybe there’s not necessarily the learnings to capture because you’re going alone. Tell me a little bit about how you did those risk assessments.

Yeah, well, I’ll talk about the iterative approach second. Beforehand, though, in the two years, that was just doing the research. When you haven’t been there, you’re going to have to just learn from those that have documented what they went through. We We’ve basically made a list, a register of what we’d be up against. We’re doing qualitative risk assessment here where we look at the relative impact and likelihood. If the relative impact is high or catastrophic in the case of death, that’s where you have to focus your mitigation strategies. And so, for things like avalanches and areas that we knew were volatile, like the kombu icefall we have to go through, where there’s about 50 of these crevasses in the ice that are hundreds and hundreds of feet deep, and we’re crossing them on aluminum ladders, tight end-to-end. And you go through that section six times. How we would mitigate that section, for example, is by the time of day we would go through. The Kumbu Icefall moves at 4 to 6 feet per day. These huge chunks of ice that are basically a frozen waterfall you could think of as this glacier, the Western Kum glacier, breaks off between two mountain peaks.

And so, it’s just a rubble of ice, except some of these ice chunks are the size of apartment buildings. It’s volatile, it’s volatile. It’s dangerous. And on the south side of Everest, it’s claimed a lot of lives from falling, seracs, or what they call those ice avalanches or those ice chunks. And so, we would go through it. If we wake up at one o’clock in the morning, try to get through all the way or the majority of the way before the sun, even at the ice, because the majority of that movement of ice happen when the sun hits it and you get expansion of the ice. And so that’s a way that we’d call that a mitigation strategy. And we tried to have those types of mitigation strategies for a lot of the other risks, falling risks. Make sure you’re clipped in. Make sure you have some redundancy when possible and in place. So that’s the upfront, how we might approach it. So now you’ve got this… Once you reach base camp, 17,000 feet, now you’ve got to start doing an up and back approach. So that’s when you make the push through, you’re noting even the mistakes you make, right?

So that you can learn from it on the next go around. The first time we climbed through that Kumbu Icefall, we were 13 hours getting up to camp one, and we barely crawled in. I mean, we were just completely spent. And one of the mistakes we had made is we had some nice to haves in our pack. We thought, well, when you get to Camp 1, it’d be nice to have an extra pair of socks, an extra pair of long John’s. Things that at the time seemed logical. Well, we learned our lesson. If it’s not critical to your safety and success, eliminate it because you can’t have any extra weight going through there. And so that’s the type of thing. We make the adjustment. We just cleaned house and made sure we just had the bare minimum we needed for safety and success. And then the same goes for how we navigate and approach some of those. There’s lots of vertical ascents and vertical repels in the icefall as you’re clamoring over these huge ice seracs. And also, just the technique in crossing these ladders. Because over that two-month period of climbing, we’re probably crossing at least Well, we’re going through six times, so 300 ladders.

And so, we would learn, we would work together a little bit to try to… When there were the loose safety ropes, the person crossing, it doesn’t give you much leverage side to side. But if one person held the rope as tight as possible from the side, it gave the person crossing a little bit of stability in terms of back and forth. And so, we developed these strategies that made things safer. And that’s the key to an iterative approach, is you take the feedback and the real-world experience from the iteration you’re in, and then you use that to make adjustments. And the adjustments are the key, because just noticing it doesn’t do much. And a lot of organizations want to seem agile, and so they break things down into small little phases. If you’re not making adjustments, you’re not You lose the benefit of an agile approach, an iterative approach in particular.

Here you have the advantage of it sounds like, doing it then going back down. You learn and then you go in again. But in business, you don’t always have that opportunity to try something, go back, and then go for real.

Well, it depends on the approach you take. I mean, the idea… I’m very much an advocate of an agile approach. And so, when I work with organizations, often we’re trying to figure out how we can Incorporate iterations, even on a smaller scale. Maybe it’s a little prototype you can put up. Maybe it’s getting an idea or something you’re rolling in front of a small user group before you invest all the time and energy into developing the full product. That’s the idea of iteration when it comes to a business environment. 

Yeah, makes sense. Now, a lot of the themes, because you were going it alone with the Sherpas, obviously, the one thing you should have less is complacency, right? Because complacency is the risk when I’ve done it too many times, they start getting comfortable with a particular task or function, so my risk awareness starts diminishing. What’s the right balance, right? Because you experience is good. Having been there before is good, but then that complacency can set in. In this case, you had probably no complacency, probably heightened awareness risk.

No, I think complacency was still a major They’re a risk and challenge for us. If you talk about crossing those ladders, because we’re crossing so many, it becomes old hat. And I can recall even at times being, well, because it takes energy to grab the rope and clip in all of that. And I’d say, well, it’s a short little cross. Maybe I should just try it without the rope. And I’d have to catch myself and say, well, you better just clip in here because, well, you need something. Should something go awry? And so, I would say it’s not like you’re always faced with complacency. What I thought of complacency, I think it’s tied in some way to the way our minds categorize things to save mental computation power. This is actually how bias arises. We don’t have the cognitive capacity to fully process everything that we’re taking it through our five senses. What we do is we take a cursory glance; we attribute the characteristics, so we don’t have to mentally process it. It’s tremendously beneficial in saving, what would you call it, cognitive processing power for us because we just don’t have the ability.

That’s what the complacency is, I would say. And so, your mind’s always trying to do that. We simplify things, glance at the latter, look, let’s just automatically do what we did the last 50 times. And so, then it’s up to the rational side of your mind, I would say, to make that analysis and say, oh, no, I better just devote the cognitive Sure. Capacity here because otherwise it can run into challenges. I guess that’s a long way of just saying, well, you’re always faced with that challenge of complacency, and you almost have to be complacent in some things because otherwise you’ve used your limited capacity in thinking about them. In the ladder example, it might be, well, I don’t think much about the integrity of the snow before the ladder, because otherwise, if I spend too much time-wasting capacity in thinking about that, I won’t have the capacity with the ladder, something like that. It’s a balance.

You talk blind spots, essentially, in terms of where we start minimizing the information, making some shortcuts in terms of our decision making. As you said, I mean, our brain uses a huge amount of energy on a good day. You’re in an environment where there’s a lot less oxygen, which means your cognitive abilities also get diminished. A lot of the case studies where things went horribly wrong on Everest were around blind spots starting to set in, whether it’s overconfidence or a desire to reach the summit that starts… You start getting task focus on reaching the summit, even if there’s maybe changing conditions in front of you. Tell me a little bit about how you managed some of the blind spots in this environment.

Yeah. Well, because in the end, your approach ends up being a hybrid between that which you spent two years of laying out and developing. And so that might be what we call the processes that you’ve established and the evaluation of the real-world risks and challenges that are ahead of you. And getting that balance right, it’s hard to… It would be hard to come up with a rule-based approach to which one you should put more emphasis on because it’s in the moment you want to be making sure you’re considering both because either too much emphasis on one or the other can be fatal if you Would you just focus on the heat of the moment and ignore everything you’ve learned and studied, that’s led to all kinds of disasters and vice versa. So how did we make sure we noticed those blind spots? Some of that I would say, I don’t know if I can be hard to articulate it. I would say those teams that were successful, they had enough experience with other adventures and challenges in life that they naturally notice things before it was too late. In some ways, that’s also the… 

That’s how you build resilience. Our lifestyle was one of a lot of different adventures and challenges. Now, they weren’t the same as the challenges were faced on Everest. But when you’re trying to problem-solve or even notice risky situations, your mind thinks back, mostly subconsciously, and extrapolates from those ways that you solved other complex problems. Maybe it was winter camping or whitewater canoeing. It’s not the same as you’re faced in the moment, but you can extrapolate from that. That’s not something, per se, you can just learn in the moment. That’s just, you might say, the advantage, if we bring it back to the workplace, that’s the advantage of someone that has worked in in a dangerous industry for 10, 20 years, where they can, if they don’t allow themselves to become complacent about it, they have enough of those data points from the past that it brings it to their attention quickly.

Tell me a little bit about how you bring these stories of Everest to the workplace, because you talk on agile workplaces, you talk about safety. Obviously, here we’re really talking about Everest and the connections to safety. Tell me about how you help bring those connections with different audiences.

Yeah. Countering is an analogy for overcoming challenges in life or in work or business on the way to accomplishing something of value. It really is a great analogy for exactly that. And so that’s what I do when I do my programs. If you just do a program on the, let’s say, the safety aspects or the agile aspects, you see your audience glaze over, right? It could be a little bit dry. I found to keep it engaging and to be beneficial and so people can remember it, you have to tie it to some story or emotional incident that people can remember. And so that’s how I use my family’s Everest story. And it’s really quieted an emotional exciting story. And so, it keeps people captivated and drawn in. And there’s just so many parallels to the industry that in general, I use a short mountaineering example of why it’s important to empower people or maintain a future mindset or how we resolve conflicts. And then I bring in more of the technical aspects, graphs and things that people can apply in their own work. I think as humans, that’s how we learn. We learn when we can make an emotional connection to the story.

We remember, at least.

We remember it, yeah.

Yeah, that’s worked great. I don’t just bring in my mountaineering ventures. I went through my own mental health journey in my younger years. I have the engineering stories. And so, whatever is most applicable to the audience or the theme or what they’re trying to learn, that’s when I bring in those examples.

Thank you. Alan, you’ve got a book as well that you’ve published. Tell a little bit about your book.

Yeah, well, two of them now. My first one is just called The Family That Conquered Everest. It’s got sections from each of my other family members as well. And so, it’s quite a, let’s say, crazy adventure story with a lot of life lessons. But For folks, my new book, it’s called Summits of Self, the Seven Peaks of Personal Growth. And that one’s really more of a deep dive into yourself in psychology. There’s a psychological safety aspect to that. It really has a deep mental health focus. In my younger years, I had quite a severe social phobia and anxiety disorder, which is known as generalized anxiety disorder. And that plagued me for a lot of years. And what got me so interested in the human mind and psychology, all of that. And I would say surprisingly so, because my background is a technical background. It’s pretty odd that I would even and go down that psychological path. But I started studying the human mind and I started developing and reading about and developing my own strategies. And then some of them worked. Now, it took me a long time of trying different things, but Some of them were cognitive games, I would call them, of how I would think back to situations and rewrite the ending, view things in a different light, for example.

And they seem silly at first, but then I would notice when I would If I were to think of those situations, I wouldn’t have the same negative emotional response. Then I doubled down. I was excited and motivated to continue on that path. I still am. I just love reading about strategies and trying to better yourself in your mind. So that’s what that book is all about. I go through seven internal summits. The summit of self-motivation, the summit of self-resilience. And so, you got to like psychology a little bit and taking a deep dive into yourself. But I’d say on that book, I get more when I get emails or people that there’s feedback from folks. For me, I’ve just realized, well, this is pretty… I thought I was the only one that had these sorts of challenges with anxiety and so on. And the more I do programs in the mental space, the more I realize this is the internal summit that so many people struggle with, and you just don’t see it.

And if somebody wants to get in touch with you, if somebody wants you to come present or talk about any of these topics, specifically around safety, how can they do that?

Probably my website would be the best. I got lots of good information on there. It’s just allanmalary.com, A-L-A-N. There are a few different ways to spell Alan, but I’ve got a bunch of videos and things on there.

Excellent. Well, thank you so much for joining me, Alan. Really appreciate you coming on the show.

My pleasure. Thanks, Eric.

Thank you for listening to The Safety Guru on C-suite Radio. Leave a legacy. Distinguish yourself from the past. Grow your success. Capture the hearts and minds of your teams. Elevate your safety. Like every successful athlete, top leaders continuously invest in their safety leadership with an expert coach to boost safety performance. Begin your journey at execsafetycoach.com. Come back in two weeks for the next episode with your host, Eric Michrowski. This podcast is powered by Propulo Consulting. 

ABOUT THE GUEST

Alan Mallory is an international speaker, author, and performance coach who is passionate about reaching new heights in all that we do. He has a degree in Engineering from Queen’s University and a Master’s in Psychology from Adler University, giving him a well-balanced approach to the inner and outer challenges we all face. Building experience through a lifestyle of adventure and challenge, Alan embarked on the journey of a lifetime and set a world record on Mount Everest along with three members of his immediate family. He believes in empowering people and embracing an agile mentality focused on relationships and results.
For more information: https://alanmallory.com
Alan Summit-Ridge
Both-of-Alans-Books

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The Importance of Not Letting Complacency Set In with Alan Newey

The importance of not letting complacency set in

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“We’ll never realize the accidents we prevent, but we sure will know the ones we don’t.” In this episode, Alan Newey details the sequence of events that led to a devastating workplace incident in September of 1999. The plant where he had been employed for 15 years had placed production over safety, and the voice in his head knew he hadn’t received the necessary training to do his job safely. Alan highlights the role that complacency and comfortability play in workplace incidents and the need to speak up to work together to send every team member home safely.

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Real leaders leave a legacy. They capture the hearts and minds of their teams. Their origin story puts the safety and wellbeing of their people first. Great companies, ubiquitously have safe yet productive operations. For those companies, safety is an investment, not a cost. For the C-suite. It’s a real topic of daily focus. This is The Safety Guru with your host, Eric Michrowski, a globally recognized Ops and safety guru, public speaker, and author. Are you ready to leave a safety legacy? Your legacy success story begins now.

Hi, and welcome to The Safety Guru today. I’m very excited to have with me Alan Newey. He’s a safety motivational speaker with CNBC Safe in Australia. He’s been unfortunately part of a workplace accident, lost his dominant arm in a conveyor accident. So, Alan, welcome to the show. Love to hear your story, really in terms of what happened in that role and some of the core themes around that you talked about when you speak to different organizations.

Yeah. Thanks for having me here. This is really important to me for people to hear the message because I don’t want people to go through what I did, especially my better half. Kathy doesn’t want the families to go through at all. And I’ll get into that. But a little background on it. I’d actually been working for the company for 15 years and I’ve done the role that I’m going to describe 4586 times before my actual accident over 15 years. The accident was September 30, 1999. And I can tell you exactly what time 735. It doesn’t matter what the press says. They said 747, 35. I was there. I should know. But no, I just left the home in the morning. This is a kiss goodbye roll up to my website a little mate that I’ve been working with for 15 years. He started work at the same place about two weeks before I did. And we’re just joking around like normal. He was a little short guy, five foot six. And I make Snow White and Seven Dwarfs jokes about him every single day. I was a heavier set guy, so he’d make set jokes about me. 

And we had a great working relationship. And we got down to this place, the plant that I was working, which would load 112 trucks a day on average, 34 times to a truck, eight minutes to a load 100 trucks a day. And he’s only five foot six for a little mate. And I’m six, too. And he wasn’t feeling well. And it was his job this day to drive cranes and operate the conveyors up high. And I was supposed to control room downstairs. Well, he wasn’t feeling well, so we swapped roles and we’ve done that before. We look after each other. I went up and started to adjust the conveyors and make my way up to the crane. And as one of the incubators is always tracked out to the side due to moisture from product or urea. It’s a fertilizer. And we have to dry the belt down and track it back into place. And the training I was showing, and he was showing was to grab this little green bucket with some drying dust inside it, reach inside the moving conveyor, throw the dust on by hand, and then once the track back into place, start the next section goes to the crane.

When I was blowing, this drawing dust belt didn’t come back far enough. So, I threw one extra handful of dust, which normally an extra handful from the normal amount. And I heard it bang. And I thought nothing of it. And I went up and looking up and down the conveyor looking for this noise that was in the machine. And I went to scratch my head, but there was nothing there to scratch my head with. That noise was my arm going around the machine and I felt nothing. No pain, nothing. 

Wow. 

Nothing at all. So, you could say I said a few explosives is I climbed down a 30-foot ladder running out to the front. My little workmate with a shock horror in his eyes has come over and jumped onto a stunt to try and stop the bleeding, which he couldn’t because what we didn’t know at the same time, it actually torn the chest on the inside at right angles. The chest was pointing at right angles on the inside. Now this is where my little mate owes me for beers. And I’m getting delayed because of the way it affects people. He owes me a few beers for this because he passed out. But he was hanging off there. He kept his strength on there. So, he’s still hanging on. So, I picked up my good. I’m not carrying that little high in the first place. So, then it all started from there. I played a high grade of tennis. I dumped Australian Open on the lines and all that beforehand. And the police officer who showed up to the accident. This is where it affects different people that people don’t think about. The police officer who showed up to my accident was a man of mine who I played in a tennis tournament three days before. 

And he just happened to be the police officer. He was sent to my accident. When he walked in the room, he’s gone into like a shot because he knew who it was. And down the track a little bit, he challenges me for a rematch because I haven’t got a double handed backhand anymore. But he’s not getting it, I can tell you now. And then it all went from there. Five reattachments on my arm to try and save it, which I couldn’t. In the hospital, they told my better half they only had 2 hours to live, and she had to make plans after its reattachment. So, she was trying to get through and with my family. So, I can’t only imagine what she’s going through. They took me back into the surgery and they gave her an. A four piece of paper, would you believe? And she had to sign for this. We’re going to pack Ellen back into surgery. Police sign here. And it was removed all of them permanently. Sign and date here to cover the backsides. Legally, they removed it. One of the doctors made a little clamp about that big about 50 cent coin type thing in Australia.

And it was lifesaving, that little clamp they put inside the chest with the 300 staples of stitches already holding me together. Saved my life. 2 hours later, I was watching television and then everything really started, really started with the rehabs and the things and wife goes through and everybody else. And it’s still going on today, 20 years later, and it hasn’t stopped.

So, tell me a little bit about some of the follow-on effects. You talked about your significant other at the time when you have an injury, the effect is significant on everybody. You talked about the police officer telling me about some of the following effects because it’s your injury and what happens to you. But there’s also a significant effect, everybody that you care, and you love. 

Yes. And I think myself, the impact on the others after my incident is actually greater than mine. It’s even greater. You’ll find out who your friends are and who can’t deal with it and people you’ll never see again. My mother-in-law rested us off. I’m still alive, mind you. And she put on the black outfit like I did the Greek. So, I was meaning to a Greek family, and she put on all the Greek outfit, all in black, and she’s doing all the things and everything. My mother went quiet. My father, he worked at the same company for 47 years and retired three years before my accident. The culture was they never spoke about safety. Safety was never mentioned, really on that site and never, ever mentioned on that site. It was always production ahead of safety. So, we all pick our jobs and all that type of thing and the profits up, I guess. So, he was kicking himself. But that’s an even older culture than me. Can understand that because the culture built up over 100 years like that. A father-in-law, he reacted differently where he actually came up to the bedside with his worry teams. 

Clicking them in my ear drove me crazy. And he still got that thick European accent. And he’s gone to me, Ellen, you know, die. If you’ll die, this is no good for me. You sign contract. Kathy your problem. She must stay with you. And that actually helped a lot. Believe it or not, they actually helped a lot. Because if you’re saying that’s not good for me, this is my father-in-law, right. But the biggest flow on effect was my little work mate. He was with me that day in the accident. And that’s the saddest one of all. And the one that can really today get me upset. And that’s over 20 years ago. He passed away about eight years after my accident. The stress he put himself under caused medical issues. A cancer formed in his stomach and he’s no longer with us. The doctors say maybe it wasn’t that. I know differently. In my heart, I know differently the stress he put himself under because he never accepted the fact that I got hurt and he didn’t. I was doing his job that day and I couldn’t get into his head because I’m 62, he’s five, six.

I miss being pulled into that machine by two inches, less than two inches. And I would have been pulled into that machine and made miss me. So, if he did that job that day was in that particular spot, he would have reached past that point and he would have been to that machine. 

Wow.

So, this is bad, but it’s the better of the two Eagles, if you can understand that. But he couldn’t accept it. He couldn’t accept that I got hurt and he didn’t. And that was the biggest flowing effect of the whole incident. 

So, you worked there for many years. Safety was never talked about. It was about getting the job done, getting it faster, improving profits. You had a voice inside of you. Tell me a little bit about what that was. 

When I first started there in September October 1999. Sorry, 80, 415 years before my accident, I was showing that plant where I had my accident. And this little voice inside me said, and when I showed me how to do the drying of the conveyors and all that type of thing, because I had all the front hand load of crane operation licenses, no problem. But the training was five minutes of this is how we do the job. This is how we drive the plant. End of the story. Five minutes. Five minutes is awesome. And if somebody came under that plant, that’s what I’d show you. And I’ll be putting data. Sure, because that’s all I knew. And the voice insider said, you don’t do this. This is dangerous. And they did tell me it was dangerous. And to be careful.

That’s not very helpful.

Right? No, there’s no guarding on his conveyor or anything like that. And it could mean the accident could be prevented for less than $800. But I sent a quarter of a million dollars in reacting to it. That’s the sad part about it. The money was there. But the voice was, you don’t do this job. This is too dangerous. Don’t do it this way. Speak up. But you wanted to keep this job because you got your mortgage, you got your bills, you got everything else. So, you didn’t speak up. And as time went on, the voice got less and less because you became more confident in the area, and it became second nature. So, all of a sudden you stopped listening to that voice and knew yourself, put yourself in danger with your complacency and just pushing forward. You didn’t listen to that voice anymore. You’d become part of the environment and you didn’t see the whole picture. 

So that is a really important theme because really we start getting complacent when we start doing it too often you talked about how you did it 4000 sometimes and nothing had gone wrong and present in those 4000 sometimes your voice starts going slower and less and less and you start accepting, what are some of the signs that people should be looking for to say, Am I getting complacent with this and really reflect in terms of how do I relook at the hazard in front of me? 

One of the big signs I reckon in that is when I start and I said it to myself many, many times, I’m used to this job, I know what I’m doing, I know what I’m doing, I’m bulletproof, I know what I’m doing. Don’t tell me what to do if somebody actually came past, but nobody ever did that. Anyway, if you stop listening, if you start hearing or you stop hearing that voice, that’s time to take five and get a fresh set of eyes in to look at where you’re working, and you can go do the same for their spot. Okay, swap for that thing, that’s the tower power sign. But the idea is once you become complacent and you hear and you don’t get anybody in and you just keep going, it’s hard, it really is hard. But what I should have done is step back. I did realize that I was getting easier, and the job was getting easier. If you start saying to yourself, I’ve been doing this job a long time, I know what I’m doing and then you start repeating it to other people, that’s the sign, you should be stepping back. 

You’re complacent with what you’re doing. That’s the big red flag. If you start paying for people, I know what I’m doing, I’ve done this job a million times. That’s the big red flag. You’re actually putting yourself in danger and heading towards a major incident without knowing it.

I think that’s a really important point. Listen to that voice, look for the signs that I’m getting comfortable with it, too comfortable with it, too comfortable and then kind of pull yourself. I think one of the things I was recently looking at is in aviation, they’ll go so far in many cases to make sure you’re not flying with the same crew, you’re not doing the same route all the time. So, you’re not flying Sydney to La or New York to London. Every time that we switch it up a little bit, so you have less chance of it becomes routine in many cases, not Airlines, but really trying to drive that switching of roles to same as takeoff and landing. There’s an alternating who’s responsible? Is it the captain of the first officer that’s going to be responsible for it? 

No, that’s right. That scenario sort of happened after my incident. People started doing different roles and changed around into different places. The culture of where I was. That person like Alan, knows that crane back to front. He knows that conveyor system back to front. We keep him there because we know we don’t have to watch him. He knows the job. And then the person in the maintenance hall that does something. And there was one guy who had an accident that I was working with, and he’s been in the maintenance hold for 37 years doing exactly the same role every day.

Steps in, you get completed. 

Right. And he had a major accident at our same site and went home nine months later. 

You talked about the other accident. What was interesting is there were no reports. When we first talked, there were no reports, no recordables. I think you said 463 days, is that correct? 

That’s correct. We went 463 days of no lost time injuries and no recordables because nobody reported it. Nobody reported them. Okay. After that 460-day bracket, and that was a big red flag in itself. We’re heading towards an incident without going. We had four majors in 18 months. Four majors in 18 months. And I think the average is 860,000 reportable a day. That’s ten every second. 

Somebody actually does say something which is not common. 

You’re getting over. What is it? 15,000 unrecorded incidences per minute. And they’re the ones leading to the major actions. There’s 5000 /minute that are recorded. Well, they’re doing something about it. They’re recording them. If you’re not recording them, you’re in that 15,000 bracket, which is where I was and my whole work crew was. It led to major accidents. It’s the amount of people getting hurt just because they’re not reporting very simple communication in it. If they reported things, they could do things about it. But if you don’t, you can’t. Nobody knows. 

But also, a lot of leaders start reflecting. I’ve had 463 days. We must be doing something right here. Things are safe. You see it as a leading indicator. I fixed the problem, but obviously it wasn’t. 

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No, because what it was with where I was working, they had the 463 days, and they had all this. After we passed one year, there’s this big celebration, I can tell you now, they put on drinks in a barbecue type of thing for everybody. And that type of stuff. And it was down to the fact that even when somebody did come to inspect the place, they knew they were coming. So, the place was cleaned down to make it look good or they inspected, and they always pass the test. But nobody ever picked up no guards. And I asked for a guard for that belt, and I was told it was too expensive and the guard would have cost less than $800. And they went a quarter of a million dollars’ worth of guards after the accident, in reaction. And if you could have seen the guard they put onto it, that actually caused my workmates risk than putting them at risk with the guard they put on there. It was so big and so massive you couldn’t move it. The safety system to protect them was on the inside of the guard and they couldn’t reach it. 

What solution is that? Because everybody got scared with my accident, I think being the fourth one in the list. And when they got scared, that’s when everybody was running and ducking for cover, that type of thing, they’re getting wrong legal advice. That’s where all the legal people come in and then really make the waters muddy and murky because everybody’s trying to think, what do I do now to cover my backside? And that’s what it got me. They got through it all, but it was years. It wasn’t just done overnight. The plant closed down. Five years later after the 2012, I think it closed down. Why? Because it was unsafe. 

Oh, it was shut down for being unsafe.

Yes. Not because it was unstoppable profitable. Not profitable. They were making millions and millions of dollars every week. They had to do all these improvements for safety. And they reckon it was better for them just to move the plans to another C-suite and rebuild the whole structure. So, where safety was, they were told production would keep their jobs. It’s not true safety would have caused their jobs. 

But too often people don’t look at that way. When you speak to audiences around your experience and some of your learnings, one of the themes I know you talk about is around regret. Tell me a little bit more about how you impact that theme and the stories there. 

The regret I have personally is one thing I can listen to my wife when she drove past that plant one day and she’d never been on site, never looked inside the four walls, and she came home and told me, leave the company, there’s going to be an accident there. She just had this feeling.

You just had this feeling? Yeah. And me being the mail and everything else and headed about it because I actually did love what I was doing. I turned around and said, I’ve been here for almost 15 years. I know what I’m doing. Don’t worry about it. Everything’s fine. Four weeks later or six weeks later, I had the accident. 

So, I regretted not listening to her, putting her through all the stuff that she went through, all the house she must have had gone through. And she kept a lot of things to herself during that process to try and protect me. And I did the same thing. And then almost causes a family element breakdown post thing. I walked past thousands of times on that plan, thousands of times. And I saw things and I had closures and all that. And I did the same thing, not reporting them. Same with my little Workman bosses walked past the whole thing. Nobody ever spoke up. And everybody knew was dangerous. Everybody knew it was dangerous. And when the accident happened, the big word that came out of everybody, why didn’t I do something about it? Why didn’t I speak up? I’m going to regret this for the rest of my life. 

And now they all live with it. And I see some of them 20 years down the track and run into them because we all live in the same areas. Yeah. And they say the same thing to me. Why didn’t we speak up? We had four people seriously heard at sight because we didn’t do anything about it and we all lost our jobs anyway. So, what was the point? If we spoke up for our workmates, we all have our jobs. We’d all be playing tricks on each other and having the fun that we were having and going home to our families. 

Speaking up is not that straightforward. It takes a climate and environment where people create an environment. The leaders create an environment where you’re comfortable speaking up. Everybody, yes, does have that responsibility to speak up when they see something that’s unsafe. But also, I’d say there’s a leadership responsibility to say, am I creating this at all my sites, all my locations? Are people comfortable speaking up? Am I seeing near misses being reported? Am I seeing people talking about concerns and are those being addressed? 

They weren’t people as they just walk past. They lived with the regret of not acting up. And they just keep wishing they did act up and speak up about it. Because when I actually got around to the plan after my accident and spoke up, other people started to speak. They started to talk to each other. They started to communicate with each other, realized that they all wanted the same thing and that’s for people to go home and enjoy life. And if they were on that wave plan, even just, hey, Eric, if we could fix that, we’re going to possibly save an incident from happening. And it all moved on from that. Because the thing is, what they all realized too late is we’ll never realize the accidents we prevent. But we are sure as we’ll know the ones we don’t. 

Right? Absolutely. Well said. But I think your message as well around focus on the bottom line won’t get you there because the cost of serious injuries are expensive. 

And not just the legal costs, not just the insurance costs, but the toll on everybody else that’s involved. 

You can’t replace him with me. You can’t replace what your wife, your significant other goes through your family and all that. But to give you an idea, just an idea. The accent was preventable for less than $800. There was an airline in this shed that I work which could have been produced for under $100. It would have prevented the accident. Now that I’m missing the right arm and it makes it blunt, that little Bolt that’s sticking out at the end is $14,000. Okay. This is $0.50 from a hardware store, which stops me from ripping the shirts and T shirts. If I don’t put it on, I’ll rip the shirt with a Bolt. But I’ve been through four leagues so far. This is a robotic limb and it’s controlled by brainwaves, so I can open and close it with my hand and operate to have a drink. I don’t even write a sentence with it, but it doesn’t replace the real thing. It’s just an A, but it’s a quarter of a million dollars. Australia in a survey about 170,000 US. I don’t want it. I would love to throw it out the window, no doubt, but it’s something I have to use because it straightens my spine up and stops future medical issues.

It keeps you in shape because I’ve no longer have the weight there. So, the spine starts to move. So, then you get back pain and it causes other issues down the track. 

All these following effects. 

Yes. You’re always living with going to the doctors, putting in a request for something else because of the incident. And then you’ve got to jump through all the medical boards and all the hurdles and all that other stuff. One thing that I love to talk just mentioned to you, that was a flowing effect of my wife. She got a letter just in, a little letter sent to her in the mail, and she could have got this day one and it was to look after her because all the people looking after me when I’m in boys looking after me, she just sits there. But she could have got somebody to talk to or counseling or something to help her. She received a letter stating that fact. There’s people there to help her, but she got the letter ten years after the accident, ten years, ten years later. 

Unbelievable.

On this, because if I had a right arm, I swear on the Bible and all those things there. But my doctor got a letter about me, and I was getting interviewed every three months for three years. So, there’s three years of my life lost being interviewed every three months by investigators. And you couldn’t forget the accident if you wanted to. My doctor was getting the same 22 questions but had to answer from a medical perspective. Okay, so this time we got 23 questions. Now, if I was to ask you what the 23rd question was because it upset Kathy so much, she wanted to go down in the head office and go postal with everybody, and I had to laugh it off, what do you reckon the question would have been? 

Okay. What was the likelihood of Mr. Newest condition to be proved and the prognosis towards the limb growing back? 

Got to be kidding.

I’m not somebody one of their officers actually asked, would the arm go back?

But cutting was not impressive. 

I’m sure she wasn’t. So, I think that the message here is it’s more than financial like, as you said. But I think organizations also need to look at it in terms of how do I drive safety? If I drive safety, I’m also driving. Like you said, the plant would have probably still been operating. All these following effects. It looks like a cost benefit analysis, but it’s so. 

And also, a good business is a business that’s safe. 

And a good business that’s safe is also going to be a productive and a successful business it is because part of the flow and effective they’re closing the plant was 54 of us lose their jobs, permanents 112 part time and casuals lose their jobs. The little shops where you buy your teams next door, we’re gone. 

Because we’re gone. The flow on effect from an incident like mine was not affecting just me, my family, workmates, friends, and all that type of thing. But the little people that you’ve built up relationships in the little shops around you for 15 years and you never see them again. It was like a little village if you wanted to say it and it’s all gone. 

It’s horrible.

All because safety wasn’t taken seriously. 

Alan, I really appreciate you sharing a story. I think it’s an important message for a lot of organizations. You speak a lot about safety motivated organizations and team members around safety. Somebody would like to share your story, bring your story. How can they get in touch with you? Is it through CNB Safe? 

Yeah, cnbsafe.com James Woods runs it and he’s a very good friend of mine. And we were in our apartment. We are both involved in major accidents now. We compare who’s got the worst one. The ball plays in a wheelchair and I go, I can push you in circles. And he goes, well, I can swim straight. You can’t. I can find my shoelaces up. You can’t. So that’s the flow on effect. Tie my shoelaces, one hand, put on your pants. And to everybody I’d say this, go home, drop your pants. I mean that in a nice way. Drop your pants, grab an Apple, and put it in your dominant hand. Then try and put your pants on with your other hand. 

Right. 

And that will give you an idea of straight away. What’s like with one arm?

Wow.

It’s just a simple test for CNB Safe. I go anywhere and I’ve one of the few people that can tell the CEO of the company and I’ve done it to some major companies. If they don’t pick up their ass and they gain you’re going to jail, and I’ve said it in front of the workers and everything and that’s not it. I’m not here for that. I’m here to make sure he does his job. You do your job, and you all go home safely.

Ultimately, everybody has to come home safe.

That’s right. And everybody’s going to work together. That’s it. 

Alan, thank you so much for coming on the show. Really appreciate you sharing a story and have a wonderful rest of your day or morning for you. 

Thank you very much.

Thank you for listening to the safety guru on C-suite radio. Leave a legacy distinguish yourself from the pack grow your success, capture the hearts and minds of your teams. Fuel your future. Come back in two weeks for the next episode or listen to our sister show with the Ops guru, Eric Michrowski.

ABOUT THE GUEST

Alan Newey is a survivor of a workplace incident. He lost his right dominant arm to a conveyor belt in September 1999. For over 13 years, Alan has been presenting to various groups around Australia on the effects of his workplace incident and the impact that it’s had on himself and his family. Alan speaks from the point of view of an injured worker and gives a real insight into what happens to you during and after such a life-changing experience. Alan is extremely confronting on the issues and effects of a workplace incident and his presentation not only addresses the sequence of events leading up to his incident, but the flow-on effects such a life-changing experience entails.
For more information: https://cnbsafe.com.au

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