safety at tmuk · 2018-07-15 · what is kyt ? • kyt = kiken yoshi training = hazard observation...
TRANSCRIPT
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
Gavin Armstrong – Head of Health & Safety
Safety Commitment – “Follow the rules and STOP any unsafe situation”
Safety at TMUK
TOYOTA MOTOR MANUFACTURING (UK) LTD
Health & Safety
Toyota Manufacturing UK overview
Burnaston, Derbyshirevehicle manufacturing
Start of production Dec 1992
2,430 employees (incl. 124 agency)
Deeside, North Walesengine manufacturing
Start of production Sept 1992
601 employees (incl. 153 agency)
Both plants represent a £2.5 billion Investment
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Background
TMUK's H&S Management System has developed in line with the recognised “Safety management maturity model".
“Change focus over time, to continue improving safety performance”.
At the same time we must continue to maintain and improve are existing systems.
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Background
Engineering - Many activities over the last 20 years to make safe equipment and safe environment.
Systems - Structured H&S Management System- H&S Procedures addressing our key risks
e.g - work an height- contractor management
- Simple Guide cards
Engineering
TOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Background
Systems - H&S Training
H&S training for supervisors
H&S procedures training
Licensed work training – for specific risks (e.g. crane use, FLT)
Risk assessment / hazard awareness training
Classroom based
Site based – KYT activity – led by Team Leaders
Systems
TOYOTA MOTOR MANUFACTURING (UK) LTD
What is KYT ?
• KYT = Kiken Yoshi Training = hazard observation training• KYT is one of our key training tools to raise hazard awareness.
TMUK Safety Culture Development
It is a structured team training session, done 2/month.
Encourages Members to identify hazards.
Empower Members to fix the problems themselves.
And by focussing on eliminating hazards, we reduce the risks of incidents occurring.
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Background
Systems - Reporting and Yokoten (sharing)
Clear systems for reporting incidents
Investigation and countermeasure prevent reoccurrence
Quick Near Miss Report developed to improve level of reporting,
by reducing the paperwork burden on supervisors.
Yokoten
By sharing the learning between Toyota affiliates and contractors
we can prevent incidents occurring in other areas
Simple, key point report
Systems
TOYOTA MOTOR MANUFACTURING (UK) LTD
0
10
20
30
40
50
60
All Accident FR
TOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Background - Behaviour
Despite the continued level of focus on health & safety we have seen a plateau in our H&S performance
Unsafe Situations
Unsafe Behaviour
The results demonstrate good progress in terms of “engineering” and “systems”. Focus going forward must be on “safe behaviours”
Behaviour
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Current Activity
Safety culture development activity started in 2008 We have used the DuPont – Bradley Curve as a model to measure against
External MotivationCOMPLIANCERules, Procedures, Protocols
Internal MotivationCOMMITMENTFelt Leadership, Role ModelingInfluencing, Engagment
“I follow the rules because I have to” “I follow the rules because I want to”
Natual Instincts Supervision Self Teams
Reactive- Safety by natural instinct- Compliance is the goal- Delegated to safety manager- Lack of management
involvement
Dependent- Management commitment- Condition of employment- Fear / discipline- Rules / procedures / training- Supervisor control- Value all people
Independent- Personal knowledge,
commitment and standards- Personal value- Care for self- Practice and habits- Individual recognition
Interdependent- Help others conform- Being others' keeper- Networking contributor- Care for others- Organisational pride
Inju
ry r
ate
sBehaviour
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Current Activity
First step to understand where we are on the curve. Climate survey / external audit
Natual Instincts Supervision Self Teams
Reactive- Safety by natural instinct- Compliance is the goal- Delegated to safety manager- Lack of management
involvement
Dependent- Management commitment- Condition of employment- Fear / discipline- Rules / procedures / training- Supervisor control- Value all people
Independent- Personal knowledge,
commitment and standards- Personal value- Care for self- Practice and habits- Individual recognition
Interdependent- Help others conform- Being others' keeper- Networking contributor- Care for others- Organisational pride
Inju
ry r
ate
s
TMUK Status
Behaviour
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Current ActivityBehaviour
Toyota’s Philosophy - “The Toyota Way” – provides a solid foundation
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Current Activity
How to achieve?
What is an interdependent Safety Culture? What does it practically look like? Where are we now / what is the gap? What do we need to do next?
Interdependent Safety Culture
Fully Engaged Members Belief / Will
Clear Practical H&S ProceduresJust / Trust / Respect
Leadership CommitmentVisibility / Participation / Monitoring
Knowledge
Understanding
Skill
P
D
C
A
EffectiveCommunication
RecognitionFeedback
Challenge/CoachingListeningBriefingTraining
Resources
PrioritisationTime
FinanceMonitoring
Action
Our visionTo establish TMUK as the benchmark for Safety Culture
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Current Activity
Developed the key principles for a TMUK Interdependent Safety Culture
with clear key points describing each key principle
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Example activities
Developed the key principles of an Interdependent Safety Culture
Set an example which is easily observable by Members Make (and personally communicate) passion and vision for
health and safety
Daily Safety ½ Hour Directors join once per week Includes members
5 Walking Rules, eg. Point and cross Hold the handrail
Behaviour
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Example activities
Developed the key principles of an Interdependent Safety Culture
Take direct and rapid action to identify and resolve concerns Share learning to prevent reoccurrence - never allow a similar
accident to reoccur
Quick Near Miss Reporting System Significant Incident Reports Shared across Toyota
Behaviour
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Example activities
Developed the key principles of an Interdependent Safety Culture
Consistently recognise and praise safe behaviours Utilise recognition systems to reward safe behaviour
Individual H&S Recognition System Director Presentation
Behaviour
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Example activities
Developed the key principles of an Interdependent Safety Culture
Relevant, straightforward and sincere communication
Annual Directors Safety Presentation All Supervisors attend
Safety calendar New safety message each day
Behaviour
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Refresh & Re-energise KYT• Reformatted document• Set KYT day• Leadership commitment, ownership by demonstration
Roll-Out MethodDIR
GMs
Snr. Mgrs.
Section Mgrs.
Group Leaders
Team Leaders
Team Members
KYT activity carried out with Directors & GMs, then cascaded through Snr Managers & SMs to Group Leaders, Team Leaders and Team Members.
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Example activities
Developed the key principles of an Interdependent Safety Culture
Members take initiative to work safely
STAR book Quick simple risk assessment
Behaviour
STOPCALLWAIT
SCW / Andon Give members the authority to
stop the line
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Example activities
Developed the key principles of an Interdependent Safety Culture
Learning is shared with others
Near miss / SAP reporting Simple and quick form developed Including safety awareness points
Behaviour
KYT Involves all members of the team Focuses on risks to their team
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Example activities
Developed the key principles of an Interdependent Safety Culture
Members actively contribute ideas for safety improvements.
TMAB / Manager safety tours Monthly safety tours by Union &
Managers together 8 tours a month – each
manufacturing shop
Safety working Group Engage with supervisors and
union safety representatives
Behaviour
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Summary
What now
Continue to maintain and strengthen our H&S systems. Embed our leadership behaviours. Focus on developing our Member behaviours.
We still have a long journey ahead ………………………………
TOYOTA MOTOR MANUFACTURING (UK) LTDTOYOTA MOTOR MANUFACTURING (UK) LTD
TMUK Safety Culture Development
Thank you for listening!
Enjoy the rest of your day