4 ways to achieve the next level in environmental, … · 2015-10-21 · brian duffy / tonja rammel...
TRANSCRIPT
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.
0
5
10
15
20
25
30
19
96
19
97
19
98
19
99
20
00
20
01
20
02
20
03
20
04
20
05
20
06
20
07
20
08
20
09
20
10
20
11
20
12
20
13
20
14
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 [email protected] [email protected]