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The best way to improve safety performance is to eliminate or minimize the fundamental risks in the process. Process revisions to eliminate risks include adding ergonomic aids like lift tables and powered articulating arms, or completely eliminating process steps that present a potential problem (moving excess material). Lean operations move smaller lot sizes, and have less product movement - and therefore less opportunity for accidents. |
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The DuPont Safety Training Observation Program (STOP) is a very effective method to engage the workforce and first line supervisors in recognizing and correcting safety hazards. |
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General housekeeping often goes hand in hand with safety performance. Use the 5-S Process to improve workplace organization. |
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Require the Supervisor of any injured employee to accompany that employee to the clinic or hospital for treatment. This heightens the supervisor's sense of accountability for safety, provides a chance for extended communication to facilitate root cause investigation, and dampens the opportunity to report "non-injuries." |
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Mandate that the Vice President of Manufacturing/Operations and President of the Company be notified of any lost time injury on the same day that it occurs, with follow-up notification of corrective actions. |
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Advise all local Doctors and Chiropractors that light duty jobs will be identified to fit any restrictionl. Try to keep injured employees in the habit of coming to work. Once employees spend time at home because there is no work available, it is very difficult to get them back to work. |
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Conduct an Ergonomic Review and Buy-off on all new equipment to ensure that any hazards are identified, proper guarding is in place, and lock-out / tag-out procedures are properly established and documented. |
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Web-based safety training programs are now available from many sources to effectively train employees on demand. This approach is particularly useful with new or transferred employees, who can be brought up to speed quickly rather than waiting until the next scheduled class. |
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Include safety metrics in a group incentive plan, such as Goalsharing, to provide a financial incentive to the workforce to identify and eliminate risks. |
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Define eligibility requirements for group incentive plans such that employees with lost time injuries during the period do not participate in pay-outs. |
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Conduct a Safety lottery monthly, with drawings to identify winners from the pool of employees with good safety records. |
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Demonstrate that safety is a priority by making it a prominent part of any operations review meetings with senior management. |
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Document safe work practices as part of standardized work instructions available at the workstation and require a sign-off by all operators. |
