Integrating Basic Lean Principles to Improve Safety Performance
Randy Groll
Black Swamp Safety CouncilAugust 2015
2
Purpose – Response to Survey Results
Answe r Op tio nsRe sp o nse
Pe rce nt
Re sp o nse
Co unt
Sprains/Strains 89.1% 49
Slips and/or Trips 87.3% 48
Cuts 85.5% 47
Falls - on the same level 70.9% 39
Repetitive motion injuries (ie: carpal tunnel) 69.1% 38
Incidents involving lift equipment 60.0% 33
Weather related hazards (slips and falls) 60.0% 33
Caught in or compressed (pinch points) by
equipment58.2% 32
Housekeeping related hazards (clutter induced) 56.4% 31
Incidents involving motorized vehicles 52.7% 29
Struck by object or equipment 52.7% 29
Arc Flash 45.5% 25
Injury from falling/dropped objects 40.0% 22
Falls - from upper levels 36.4% 20
Burns 36.4% 20
Hazardous materials 36.4% 20
Struck against object or equipment 30.9% 17
Combustible materials 29.1% 16
Air quality/respiratory concerns 29.1% 16
Dismemberment (loss of limbs/digits) 23.6% 13
Embedded debris (ie: wood/metal/other 21.8% 12
Drowning 1.8% 1
2
55
0
Other (please specify)
T he fo llo wing sa fe ty co nce rns imp a ct ma ny ind ustry se cto rs . Ple a se
id e ntify the a re a s o f sa fe ty ha za rd s tha t a re re le va nt fo r yo ur
wo rk fo rce . Ple a se che ck a ll tha t a p p ly .
sk ip p e d q ue stio n
a nswe re d q ue stio n
3
0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%
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Safety is a continuous improvement process. With that in mind, which of the following areas of improvementbest
applies to your work environment? (Check all that apply)
Purpose – Response to Survey Results
Sa fe ty is a co ntinuo us imp ro ve me nt p ro ce ss. W ith tha t
in mind , which o f the fo llo wing a re a s o f imp ro ve me nt
b e st a p p lie s to yo ur wo rk e nv iro nme nt? (Che ck a ll tha t
a p p ly)
Answe r Op tio ns Re sp o nse Pe rce nt Re sp o nse Co unt
A clean and organized work area - items removed from aisles,
trip hazards removed from area80.0% 44
Easy access to Personal Protective Equipment (PPE) and other
safety equipment (fire extinguishers, etc.)
61.8% 34
Auditing and accountability of work areas - checklists,
housekeeping boards, metrics
60.0% 33
A work area with items and equipment identified and tools
placed in a designated space - shadow boards, chemical
storage, etc.
60.0% 33
Identifying and labeling equipment - lock out points, machine
controls, etc.58.2% 32
Using visual controls for standardized work - visual work
instructions, utility identification and flow, indicator lights, etc.
45.5% 25
Other (please specify)2
55
0sk ip p e d q ue stio n
a nswe re d q ue stio n
4
Re sp o nse
Pe rce nt
Re sp o nse
Co unt
49.1% 27
25.5% 14
0.0% 0
7.3% 4
5.5% 3
12.7% 7
55
0
40%
skip p e d q ue stio n
Answe r Op tio ns
80%
20%
a nswe re d q ue stio n
Wha t p e rce nta g e o f yo ur wo rkfo rce ha s b e e n tra ine d o n Le a n p rinc ip le s?
Fo r Exa mp le 5S syste m (So rt, Se t in Ord e r, Shine , Sta nd a rd ize , a nd
Susta in), s ta nd a rd wo rk, a nd v isua l co ntro ls?
60%
0% (or unfamiliar with these processes)
100%
0% (or unfamiliar with these
processes), 49.1%
20%, 25.5%
40%, 0.0%
60%, 7.3%
80%, 5.5%
100%, 12.7%
What percentage of your workforce has been trained on Lean principles? For Example 5S system (Sort, Set in Order, Shine, Standardize, and Sustain), standard work, and visual controls?
0% (or unfamiliar with theseprocesses)20%
40%
60%
80%
100%
Purpose – Response to Survey Results
Agenda
Explain why and how an organization can integrate Lean Principles
• 5S• Standard Work• Visual Workplace
Practices• Kaizen – Root Cause
Analysis
to improve workplace safety
5
Lean Safety
Safety
Employee Culture of Safety Awareness to Reduce or eliminate …..
• Incidents
• Accidents
• Injuries
6
Lean
Employee Culture of improving efficiency and eliminating waste by utilizing….
• Clean and organized work processes
• Standardized and Visual work processes
• Measured and audited work processes
7
5S + Safety = 6S
5S - the foundational tool that can support both issues…
• SAFETY
• EFFICIENCY & WASTE
8
It Just Makes Sense!
SORT
SET IN ORDER
SHINESTANDARDIZE
SUSTAIN
SAFETY
5S Process Steps
Sort• Remove unnecessary items from workplace
Set in Order (Straighten)• Organize and label items for easy and efficient use
Shine• Clean work area and equipment
Standardize• Establish documented work processes to support Sort, Set
in Order and Shine
Sustain• “Routine Business Practice” – with audits and measures in
place to monitor success
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5S is more than housekeeping!
6S - Sort
WHY?
• Pinch Points
• Trip, Slip or Fall
• Incidents
• Evacuation
10
Incident
Slip Evacuation
Pinch Points
6S - Sort
HOW?
Remove unnecessary items
“Red Tag” items
11
Chemicals
Tools Materials
WHY?
• Sprains and Strains
12
6S - Set in Order (Straighten)
Lifting
85% Rule
Muri
WHY?
• Injury
13
6S - Set in Order (Straighten)
WHY?
• Burns
• Explosion
14
6S - Set in Order (Straighten)
Explosions
Fires
Chemicals
6S - Set in Order (Straighten)
HOW?
Organize and Label for efficient use
15
Workstation
BordersUtilities
6S - Set in Order (Straighten)
HOW?
Organize and Label for efficient use
16
Tools and Equipment
SuppliesEase of use – Lifting
6S - Set in Order (Straighten)
HOW?
Organize and Label for efficient use
17
Fire Extinguishers
Eye Wash Stations
PPE
6S - Set in Order (Straighten)
HOW?
Organize and Label for efficient use
18
Locks
Lock Out Machine Guarding
6S - Set in Order (Straighten)
HOW?
Organize and Label for efficient use
19
Chemical Labeling
Chemical Storage
Supply Storage
6S - Shine
WHY?
• Avoid slips, trips, falls
• Accidents
20
Leaks
Off Standard ConditionsOil
6S - Shine
HOW?
Clean Work Areas
21
Drains
Floors Lighting
6S - Shine
HOW?
Clean Equipment
22
Pumps
Mobil Equipment
Equipment
6S - Standardize
Why?
• Standardized Processes reduces risk of injury
• Understand process and expectations
• Eliminates confusion
23
Standard Work is the BEST METHOD of Performing Task
6S - Standardize
HOW?
Consistent Methods(Standard Work and Visual Management)
24
Evacuation Routes
Workstation Layout Work Practices
6S - Standardize
HOW?
Consistent Methods(Standard Work and Visual Management)
25 Safety Rules
Materials
OSHA Guidelines
6S - Sustain
Why?
• Maintain Results
• Identify Opportunities
26
Audit
Track Results
Prioritize Issues
6S - Sustain
HOW?
Promote Awareness
• Monitor
• Maintain
27
Policies Hazard Awareness Training Plan
Procedures
Kaizen + Safety
Why?
• Resolve issues with disciplined Root Cause Corrective Action & Analysis (RCCA) – A3
28
Kaizen RCCA Process
Summary
What do you currently do?
What could you do?
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Contact Information
Randy Groll D&R Continuous Improvement Systems
Phone: 419-956-1173
E-Mail: [email protected]
Website: lean6quallity.com
Mary Agostini A&W Continuous Improvement Systems
Phone: 419-261-1490
E-Mail: [email protected]