4 ways to achieve the next level in environmental, … · 2015-10-21 · brian duffy / tonja rammel...

4 WAYS TO ACHIEVE THE NEXT

LEVEL IN ENVIRONMENTAL, HEALTH AND SAFETY

Tonja Rammel Brian Duffy

Manager of E, H, & S Director of E, H, & S

Crown Equipment Corporation

Introduction to Crown 5 regional

headquarters

2.4 Billion USD

FY2013 10,700

employees

Over 500 retail locations across 84 countries

17 manufacturing plants in 11 locations worldwide

Leader in material

handling innovation

and technology

Family owned and managed since 1945

Global line of

trucks designed

to local work

practices

Innovative

fleet

management

solutions

One of the World’s Largest Lift Truck Manufacturers

Global Line of Lift Trucks

Designed to meet local standards

and operator preferences

Global Manufacturing • 17 Manufacturing Plants in 11 Different Locations

• North America Manufacturing Plants

– New Bremen, Ohio (Corporate)

– Troy, OH

– Greencastle, IN

– New Castle, IN

– Kinston, NC

– Queretaro, Mexico

Vertical Integration

Assembly Plant/ Distribution Center

Fabrication/Welding/Heavy Machining

Precision Machining

Wire Harness Motor Plant/Plastics

Electronic Assembly Mast Plant

We would like to

highlight 4 very

successful, sustainable

processes that we

believe sustains our

business by engaging

our employees to move

Crown to the next level

in EH&S.

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TCIR

LWCIR

Crown Manufacturing

Safety Incident Rates

#1 - Safety

Leadership

Committees

History and Introduction

• Engage and empower employees to increase

ownership of safety

• Continuous Improvement

• Individual Development

• Safety Leadership Committee Establishment

• Sub-Committee Establishment

• Leadership Development and Support

Committee Member Selection • Representation from all depts. & shifts • People that are considered leaders • Passionate about safety • Willing to get involved

Development of the Safety Leadership Committees (SLC)

Examples of Safety Leadership Teams

– Safety Mentoring Team

– Eye Injury Prevention Team

– PPE Team

– Lockout/Tagout Team

– OSHA Compliance Teams

– Machine Move Team

INJURY PREVENTION SAFESTEPS Regulatory Compliance Emergency Response

Material Handling &

Recyling

195 Total People Involved/Volunteered

Some participate on multiple teams

53% of Plant Involved

Plant 3 Safety Organizational Chart

Safety Specialist

SafeSteps Steering TeamK. Below/ B. Claybaugh

- 11 members

Hazardous Energy TeamL. Fleckenstein - 13 mbrs

Hand Safety TeamK. Bell - 13 mbrs

Fire Prevention TeamD. Voress - 7 mbrs

CERT & MERTT. DeNise

- 9 CERT / 6 MERT mbrs

OSHA Compliance TeamD. Voress- 16 mbrs

Ergonomic Audit TeamM. Pendergraft - 11 mbrs

Job Safety Analysis TeamE. Grillot - 5 mbrs

Stretch LeadersR. Klenke - 25 mbrs

Machine Move TeamR. Timmerman - 9 mbrs

Trip Hazards TeamM. Pendergraft - 13 mbrs

Hoist & Lift Attachment Team

R. Timmerman - 5 mbrs

Plant 3 Safety Leadership Committee

Seasonal Safety TeamD. Thacker - 14 mbrs

Drive TeamK. Bell - 55 mbrs

Lift Truck OperationsB. Holdren - 6 mbrs

New Hire Safety SponsorC. Brown - 14 mbrs

Awareness Activities TeamK. Below - 7 mbrs

Home Safety TeamD. Behr - 5 mbrs

Health & Wellness TeamK. Below - 7 mbrs

MSDS TeamD. Thacker - 7 mbrs

Core Team TrainingB. Claybaugh - 320 mbrs

Tool Inspection TeamD. Thacker- 8 mbrs

Bolting StringersTeamR. Timmerman- 2 mbrs

Eye Safety TeamNEED - 10 mbrs

Plant 3 Safety Organizational Chart

Safety Leadership Teams Effects on

Plant Culture – Eliminates injuries

– Increases plant engagement/ownership

– Promotes a positive safety culture

– Increases safe work habits

– Improves ergonomics and work conditions

– Exceeds OSHA compliance regulatory standards

– Communicates success stories within the plants

Sustaining Environmental Engagement

Common Safety Leadership Committee

Questions

– How do you begin?

– What is the structure and support for a Safety Leadership Team?

– How does any production get done with so many employees participating on teams?

– Do some employees participate on multiple teams?

#2 -

History and Introduction

• Implemented SafeSteps in All NBO and GRN Mfg plants

over last 10 years

• Presented SafeSteps to the 2011 AME Conference in

Dallas

• Ohio Manufacturers Education Council, MAPI, Ohio

BWC, SOSE and Many Customers

• Worked with Quality dept in Crown Mexico to implement

the Behavioral Model in Quality

History and Introduction

A process that attempts to change the way people behave

Uses observations and feedback

Uses positive reinforcement

Builds habits

Looks at behaviors not conditions

Can improve workplace culture, productivity, quality as well

as safety

SafeSteps Activity –

Arm Folding Exercise

How does it work? • An employee based, informal peer to peer observation

and feedback process using cards that contain the

correct pinpointed behaviors.

• We want to “catch” folks doing the right things!

• We want to positively reinforce them when they do!

• We want them to run the process

How does it work? • Plant Assessment

• Employee Run

• Steering Team

• Voluntary

• Anonymous

• Celebrations/Recognitions

• Pinpoint Cards

• Positive Feedback

• No Discipline

SafeSteps: A Behavioral Based Safety Process based on the ABC Behavioral Model Below

Antecedents: Things that Prompt Behaviors

• Safety Meetings

• Safety Training

• Warning Signs

• Instructions

What do we do when these don’t work?

Remind Restate Retrain !

Discipline !!

Consequences

Consequences

Why It Works:

Immediate, Positive, Accurate Trusted Source

The Power of Positive Reinforcement Why it Works –

Why It Works – In a Manufacturing Setting

• It’s all about employee engagement

• They become motivated

• They own it

• R+ Recognition

• Consequences

• Rooted in Behavioral Science,

and what motivates people

#3 – New Hire &

Safety Mentoring

Background – WHY did Crown change New Hire?

THEN NOW

• Day 1 – 100 slides of OSHA requirements

• NOT focused on Injury Prevention

• 10-50% of New Hires are getting injured!

• Focused on Hazard Recognition & Injury Prevention

• Focuses on Preventing Top 4 injuries @ Crown

• Engaging, Interactive

• Demonstrated Performance

• Safety Mentoring w/Positive Feedback

• Advancing Safety Culture

New Hire Process

HR & Safety Orientation

Workplace Safety Orientation

** Safety Mentor Assigned to New Hire

Hazard Recognition/Injury Prevention Modules

• Hand Injury Prevention

• Eye Injury Prevention

• Slips/Trips/Falls Prevention

• Strains Prevention

Day 1

Day 2

Weeks

1-5

New Hire Process

Hand Injury Prevention

1. Computer Based Module (CBT)

- Self paced CBT

- Interactive, Engaging

- CBT is focused on

- Hazard Recognition

- Identifying Conditions

and Behaviors

- Injury Prevention

- Integrated Quiz & Scenarios

2. Hands-On Training/Practice

3. Skill Check

New Hire Process

Hand Injury Prevention

1. Computer Based Module (CBT)

- Self paced CBT

- Interactive, Engaging

- CBT is focused on

- Hazard Recognition

- Identifying Conditions/Behaviors

- Injury Prevention

- Integrated Quiz & Scenarios

2. Hands-On Training/Practice

a) Hands-On Safety Training with Safety Mentor

b) Complete Hands Practice Sheet

- Identify Potential hand hazards in work area (while learning job)

- Determine cause (condition and/or behavior)

- Describe how to prevent the injury

3. Skill Check

New Hire & Safety Mentor

- Tell Me: New Hire discusses the 10 items from the Practice Sheet with Safety Mentor, explaining how conditions & behaviors can lead to hand injuries

- Show Me: New Hire demonstrates their ability to prevent hand injuries to Safety Mentor.

- No less than 100% is acceptable.

Then repeat this same process for Eyes, Slips/Trips/Falls & Strains.

Feedback

Positive feedback from Safety Mentors, New Hires & Supervisors: – “This style of orientation is hands-on, interactive and more personable.”

– “Taught us how to safely perform the everyday tasks, think about the little things”

– “Meeting new people, working one-on-one with safety mentor, forced me to talk with someone about safety and identifying the hazards myself was eye-opening, and having someone to go to with questions.”

– “Ability to guide/teach the new hire, and even learn

a few things myself.”

– “Having a Safety Mentor really made me feel like

Crown cares about me and my safety.”

– “The premise is awesome. This training is going

to be effective and you will see the results.”

- “New employees get the chance to recognize the

hazards out on the shop floor.”

- “There were some good finds in the skill checks.”

- “I love the idea of having real world hands on training.”

- “1 on 1 mentoring instills more of a safety priority.”

#4 - Environmental

Sustainability

Our history as a sustainable company has been proven throughout the years: 1993: State of Ohio’s Pollution Prevention Award

1994: Eliminated Solvent Degreasing

2003: USEPA National Waste Minimization Partner

2008: Ohio Award for Outstanding Achievement in Environmental

Stewardship

2009: Zero Landfill Achievement

2010: ISO 14001 Achieved and Ohio Award for Outstanding Achievement in

Environmental Stewardship

2011: Zero Landfill Achievement

2012: ISO 14001 Achieved

2014: Ohio EPA E3 Gold Status Award (NKO), Most Valuable Pollution Prevention Award (MVP2), Hosted Zero Waste to Landfill Workshop

2015: Ohio EPA E3 Gold Status Award - Plt 7

Sustaining and Promoting

Environmental Engagement

• Environmental Sustainability Events

• Zero Waste to Landfill

• ISO 14001

Environmental Sustainability Events

• Environmental Sustainability Team

• Events

• Lean, Green and Safety

• Benefits

• Rethink, Recycle,

Reuse, and Reduce

• Challenges

Zero Waste to Landfill

ISO 14001

Date

Feedback

Yes NO Given Total

NKO Environment al Cards

Put Recycling in correct container

Use hand dryers when possible

Turn off machine when not in use

Turn off lights when leaving

• Benefits

• Senior Management Commitment • Environmental Policy Development

• Management Review

• Regulatory and third party registrar support • Ohio EPA – Office of Compliance Assistance and

Pollution Prevention

• Challenges

In Summary

• In order to improve your EHS processes and get to the “next level”…

• Engaging employees in Safety and Environmental is key.

• Their ownership can provide the company with significant performance improvements.

• Crown has had excellent success with these four approaches.

• Do not hesitate to contact us for further information

Thank You!

Please complete the session survey at:

www.ame.org/survey

Session: WP/29

4 Ways to Achieve the Next Level in

Environmental, Health and Safety

Brian Duffy / Tonja Rammel

Crown Equipment Corporation Brian.Duffy@crown.com Tonja.Rammel@crown.com