Enhancing critical control management using bowties for high consequence risks at Rio Tinto

Abstract In industries where high‐consequence events can result in severe impacts, effective risk management is essential. This paper presents Rio Tinto's evolving approach to managing such risks across its mining and minerals processing operations. The destruction of the Juukan Gorge rock shelters in 2020—a site of profound cultural significance to the Puutu Kunti Kurrama and Pinikura peoples—served as a pivotal moment for the company, emphasizing the value of adopting a more holistic approach to hazard identification and control. In response, Rio Tinto launched a comprehensive risk management uplift program that extends beyond traditional major hazards—such as process safety and tailings—to include cultural heritage and environmental considerations. Central to this program is the expansion of bowtie‐based critical control management, focusing on enhancing first‐line capability within a three‐lines‐of‐defense framework. The approach integrates best practices from the Energy Institute (EI), the Center for Chemical Process Safety (CCPS), and the International Council on Mining and Metals (ICMM). The paper explores the importance of clearly defining controls and critical controls, the role of centrally defined performance specifications, and best practices in bowtie methodology. It also includes a case study demonstrating the application of this approach to a major process safety hazard.