How we got here.

Kirby Historical Timeline

• 1955 – Founded in Houston, TX (GC Firm) • 1959 – Began selling under Mes-Tex Buildings

brand • 1966 – Acquired by Kirby Industries • 1973 – Built Portland, TN plant • 1984 – Consolidated manufacturing and

Corporate HQ into single facility in Portland, TN • 2000 – Acquired by MAGNATRAX Corporation • 2007 – Acquired by Nucor Corporation

The First Steps

• In February 2010, we requested to be entered into Tennessee’s SHARP Program.

• April 2010 – First Onsite visit by TOSHA • December 2010 – Completed the last of 19

contingency items and received our SHARP Certification letter.

EMPLOYEE INVOLVEMENT

STEEL Committee

• The Safety Tipping Empowers Employee Leadership (STEEL) Committee was formed in January 2008.

• There were six teammates involved in the STEEL Committee at it’s inception. This number really would fluctuate from meeting to meeting.

• Currently there are 80 teammates involved with the STEEL Committee.

• In January 2010, we restructured the STEEL Committee and formed sub-teams to aid in the improvement of the safety culture at Kirby. •Training Team

•Management of Change •Incident Investigation •Inspection •JHA •Project Completion •VPP – Developed in March 2011

Three new teams for 2012: •Health and Wellness Team •Lock Out Tag Out Team •Emergency Preparedness Team

VPP TEAM

VPP Site Evaluation

• Section I – Management and Leadership Commitment A. Written Safety and Health Management System B. Management Commitment and Leadership C. Planning D. Authority & Line Accountability E. Contract Workers F. Employee Involvement G. Safety Management System Evaluation

VPP Site Evaluation Cont.

• Section II – Worksite Analysis A. Baseline Hazard Analysis B. Hazard Analysis of Significant Change C. Routine Hazard Analysis D. Routine Inspections E. Hazard Reporting F. Hazard Tracking G. Accident Investigation H. Trend Analysis

VPP Site Evaluation Cont.

• Section III – Hazard Prevention and Control A. Hazard Prevention and Control B. Discipline System C. Emergency Procedures D. Preventative Maintenance E. PPE F. Process Safety Management – (if applicable) G. Occupational Health Care & Recordkeeping H. Recordkeeping

VPP Site Evaluation Cont.

• Section IV – Safety and Health Training A. Safety and Health Training

On the first trip through the site evaluation, all the team did was answer yes or no. – YES we have documentation for the question – NO we don’t have documentation

– When we did have the documentation, the

information was assigned an addendum number and collected into a 6” binder.

• On the second trip through the Site Evaluation, the team began to fill in the holes.

• Once the holes were filled, these items where assigned an addendum number and included in the 6” binder.

GETTING THE WORD OUT

Flyers Everywhere!

Kirby Bingo

ARE WE THERE YET?

The Application

• After numerous re-writes to the application, we submitted the application to Jim Flanagan, Tennessee’s VPP Manager, on April 11, 2012.

• I called Jim Flanagan on April 30, 2012 to check on the application. – What did we miss, do you want more information,

etc. – We had heard the stories of VPP applications

being rejected the first, second, third, etc time they were submitted.

The Bombshell

• Jim Flanagan: How quick can you be ready for your onsite evaluation?

• Me: Well, we have a couple of consultants scheduled over the next month. What timeframe are you wanting to schedule your visit?

• Jim Flanagan: How about the 14th through the 18th onsite?

• Me: Of June? • Jim Flanagan: No, the week after next.

[INSERT CRICKET SOUNDS HERE]

ARE YOU REALLY GOING TO SAY NO?

Onsite Evaluation

• Jim Flanagan – VPP Manager • Dave Buckles – Compliance Officer • Ashley Harris – Compliance Officer • Tina Douglas – IH Specialist*

Teammate Interviews

• 35 formal interviews – one on one interviews with Jim Flanagan. – First three people picked happened to be a our

CAVE people. • Citizens Against Virtually Everything

• Approximately 200 informal interviews – – on the floor, quick conversations with the guys – Walking around the office

Contingency Items 1. Develop and document contractor pre-selection

criteria. Ensure that safety and health considerations are addressed during the process of selecting contractors…

2. Improvements to annual self evaluation process. 3. Communication of 4’ fall protection requirement. 4. Establish a preventative maintenance schedule for

retractable lanyards. 5. Use of extension chord to power heater at seam

welder. 6. Data plates on Coil “C” hooks 7. Ensure LOTO procedures are “as done”

- ensure adequacy of periodic inspections 8. Guarding of backside of 20’ Cincinnati Shear.

Contingency Items 9. Band saw – unused portion of blade inadequately

guarded. 10. Develop JHAs for robots 11. Inadequate guarding of robots 12. Develop LOTO procedures for changing weld tips

on robots 13. Inadequate guarding – Kirby lock mill. 14. Emergency Procedures

- ensure alarms are audible outside - address RR / airport

- Permit Required Confined Space – develop procedures for reclassifying spaces

Contingency Items 16. Updates to Respirator Program 17. Add SAFER devices to BBP program 18. BBP Record keeping improvements 19. Improved Carbon Monoxide signage 20. Parts cleaner solution not properly labeled 21. Purlin Press – LOTO procedures for changing shim 22. Gooseneck on fork truck should be approved by

manufacturer. Update data plate. 23. Bottled gas storage – inappropriate use of power

strip. 24. Office door in warehouse should be labeled “Not

an Exit”

Contingency Items 25. Develop provisions for contractor non-compliance

with laws/policy/procedures. 26. Flange brace punch 234 guarding

–point of operation - rotating shaft - chain and sprocket system

27. Angle shear - point of operation guarding

28. Angle Mill - Nip point guarding 29. Soffit Shear –

- guarding on back side - rotating shaft guarding

The remaining 11 Contingency items were corrected within ten days of the end of our audit.

WHEW! WE'RE DONE NOW RIGHT?

The fun is just starting!

• VPP is not the end of your journey, it is just a minor step along the way.

• The REAL work is continuous improvement. • How do you keep people energized and

focused? • How do you continue to challenge and grow

your team?