successful safety evolution brian zoeller, ms, csp vice president of safety and security neenah...
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Successful Safety Evolution
Brian Zoeller, MS, CSP Vice President of Safety and Security
Neenah Enterprises Inc.
History
Neenah Foundry is a Division of Neenah Enterprises Inc.
– Established in1872– 900+ Employees
• Union Facility
– Municipal and Industrial Castings• Municipal
– Manholes, Grating and Decorative castings
• Industrial– Trucking, Agriculture, Construction
Safety Program History
Simple Reactive Safety CultureLimited Staffing
– 1 Safety Professional• Plant and Corporate responsibilities
– 2 Nurses • 12 hour coverage
Limited upper management supportSafety program was secondary to plant
operations and overall organizational strategy
Historic Safety Results
30.5
12
3.4 2.5
12.910.9
0.73.2
9.411.4
0.32.2
0
5
10
15
20
25
30
35
Total Rate
2010 2011 2012
Calendar Year
Total Recordable and Lost Work Day Rates
NF-TRIR
BLS-TRIR
NF-LWDR
BLS-LWDR
New Corporate Commitment
New management team started to be established in early 2011
Understood the need for a corporate safety process– Decrease injuries– Engage workforce– Improve facilities– Decrease workers compensation cost
Build safety into daily tasks– Starting all meetings with safety– Holding Safety Dept. monthly calls – Recordable & Safety AIR meetings– KPI’s (JSA, Safety Walk requirements)
Adding committed resources
Neenah Foundry Safety Team
Safety Department– Shawn Sexauer, Senior Safety Engineer– Ryan Jakober, Safety Engineer– Lisa Klaver, Safety Administrator– Summer Interns
Health Services– Breanna Magley, RN - Supervisor– Kim Birr, RN– Ashley McKeown, RN– Larry Stark, LPN
Successful Safety Process Builders
Creative– Think outside the box– Open minded approach– Don’t listen to the CAVE men
Justified Work– Run controlled experiments– Understand basic business acumen– Work as a team
New Safety Process Approach
Proactive– Training
• New hire orientation (4 hours – 2 days)• OSHA training• Job Safety Analysis (JSA) creation and training• Training Within Industry (TWI)• OSHA 10/30 hour courses• Fox Valley training courses
– Safety Kaizen Events– Work hardening– Supervisor safety meetings– Focus teams (Ergo, Safety, Wellness)– Upgraded equipment– PPE development– Video creation
New Safety Process Approach
Reactive– Incident investigation– Safety blitz– Intervention programs– Safety hotline
Monitoring– RAIR/SAIR meetings – Formal hygiene sampling– Audits
• Safety walks• Quarterly union plant walkthroughs
Ergonomic Evolution
1. Utilized continuous improvement tools to track injuries (Pareto charts)
2. Created stretching programs for specific job tasks
3. Implemented Work Hardening program
4. Implement Department Stretching program
5. Utilized onsite Physical Therapy
6. Created training programs
7. Implemented ergonomic audits
8. Created ergonomic committee
9. Implementing POPE
Ergonomic – Stretching Program
Stretching Program Repeat each stretch 5 times for 5 second
Ergonomics – Work Hardening
Work Hardening Program– Work Hardening Objectives
• Decrease upper extremity soft tissue injuries in new hires
• Decrease new hire turnover• Increase performance knowledge
– Program Basis• Identified high and low impact tasks • Implement stretching• Eight week program that slowly increases the time
and duration that the new employee is exposed to the job tasks
• Acclimate employees bodies to stresses of job• Improve overall training program
Ergonomic – Training Program
Training Included– Definition of ergonomics– Description of musculoskeletal injury (MSI)
• Tendonitis• Carpal tunnel• Shoulder strain/sprain• Back strain
– Corrective actions• Quick wins• Capital projects
Ergonomics – POPE
Post Offer Pre-Employment– Screens new candidates for proper job fit– Detailed assessments ensure:
• Employee body is safe to perform the job• Employee can handle the physical stresses of job• Employee still wants to do the job
– Completed at NF Training Center• Equipment designed and built to mimic job
functions• Conditions similar to working environment (noise,
ambient air, PPE)
Ergonomics Circle of Health
Partnerships
External– Northeast Wisconsin Foundry Ergonomics
Partnership (NEWFEP)– OSHA– Advanced Physical Therapy– Blankenheim
Internal– Safety Focus Teams– Ergonomics Committee– Wellness Team– Union Management Team
AIC – Safety Software
Internet based software program that can manage and maintain your health and safety program– Used for tracking
• Injury and illnesses• JSA’s• Observations• Training• Near misses• Fires
– Actively works with our insurance carrier to track claims
– Ability to assign corrective actions to individuals, which in turn increases accountability
Safety Intervention
Primary goal is to improve an employee’s safety behavior– A tool to increase an employees safety
awareness and improve their safe work practices
Employees that meet the criteria for intervention are:– Injured but no safety violation; and– Injured more than three times in a rolling
twelve month period
Safety Blitz
An investigative team that is designed to assist the supervisor when investigating a serious incident
Assembled within 24 hours of the incident or sooner if needed
Supervisor leads the team with the assistance of safety
Union participation
Training Center
Area designed to conduct hands on training for employees– Used to give new employees the exposure of
working on the floor and handling castings in a neutral environment
– Confined space trainer– Hands on ergonomic training– Casting handling training – Will be used for POPE testing
Current Performance
Currently at 1.5 million hours without a lost work day incident
5.1
9.9
0
1.8
9.1
9.9
0.3
1.8
2.6
9.9
0
1.8
0
1
2
3
4
5
6
7
8
9
10
Total Rate
2013 2014 2015
Calendar Year
Total Recordable and Lost Work Day Rates
NF-TRIR
BLS-TRIR
NF-LWDR
BLS-LWDR
Safety Awards
Wisconsin Safety Council– Wisconsin Corporate Safety Award– 2013
American Foundry Society– Metalcasting Safe Year Award – 2013– 2013 Millionaires Safety Award
3 million hours without incurring an occupational
injury or illness that resulted in lost workday case
Historical Trend
30.5
3.4
12.9
0.7
9.4
0.3
5.1
0
9.1
0.32.6
0
0
5
10
15
20
25
30
35
Total Rate
2010 2011 2012 2013 2014 2015
Calendar Year
Total Recordable and Lost Work Day Rates
TRIR
LWDR
Future State
Neenah Foundry and NEI are continuing to change our safety cultures and improve our safety process.
We are far from complete
Questions