Transcript Imperial Manufacturing Group

The IMG’s Safety Story
Presenters:
Karen Mazerolle BN/RN
October 2010
IMG’s Goal
Change our culture
from a production with
a safety approach to
SAFE PRODUCTION
What happened to us? The Safety Issues
• We grew faster than the
company’s infrastructure.
• Contrary to our belief, safety was a
secondary priority.
• Focus was on hitting production
targets!
• Trend of accidents increased as
the company grew
(cont)
• New employees (massive rapid
hiring)
• Limited orientation and training
• Poor Maintenance Program
• In the absence of a plan the culture
defaulted to the assumption (every
body knows what to do).
• Accidents became epidemic and
culturally engrained as part of the
dangerous nature of IMG. Tough
man (person) culture!
How Big Was the Problem?
• Accidents were considered as a cost of doing
business
• Accidents were becoming more serious
• Process left completely to Work Safe, lack of
ownership
• Sense from employees, IMG did not care
about safety.
• Public perception was very poor. (Chop shop)
Workforce Challenges
Changing the attitude that “we have done it this
way for 20 years”
Encouraging the employees to speak up about
safety concerns
Convincing employees that safety is the #1
concern and it is being addressed by
management
Motivating employees that change is necessary
for improvement
Discipline around unsafe acts
What became our Focus
Addressing Urgent safety concerns to
prevent future injuries
Safety issues were addressed promptly and
employees were given feedback – building
employee trust
Implementing reliable structure for change ie.
monthly inspections, safe work practices,
scheduled communication (posters, safety
talks)
H&S training for all employees including
management
How did the process flow
Management recognized that safety
was a concern
Partnership with Work Safe NB was developed
A Health & Safety Plan was developed
using the 5 *22 model
H&S Plan was signed by the President
Employees were informed of the plan
The 5*22 Safety survey was completed by all
employees during work hours
“Original 8” of the 22 H&S Topics
1.
2.
3.
4.
5.
6.
7.
8.
H&S Policy – Responsibilities & commitment from all levels
H&S Plan – Ownership & accountability
H&S Communication – Increasing employee awareness
Identification of Hazards & Risks – meeting legislated
requirements, increased employee awareness of risk,
educational tool used during employee orientation
Control of Hazards & Risks – Specific Action Plan , target area
Accident reporting – Employee participation in safety, action
taken to prevent future accidents.
H & S Inspections – useful in identifying & controlling hazards
Health and safety educational needs assessment helped
develop an inventory of training requirements
Safe work Practice
Hand Position when Making Anti-Gust
Hazard:
Dimple punching product without a Guard in Place
Control the Hazard:
Right Right hand
holding the side of
the product
Left hand holding
the piece to be
dimple punched
Other steps taken
Plant rules reviewed with employees via safety
talks and posted throughout the plant
IMG outsourced an Equipment safety hazards
inspections and every machine was
inspected
Hazards were prioritized & necessary steps
taken
Employees were kept updated on progress
Safety items were priority – a maintenance
employee was designated to safety for 6
months
5 FUNDAMENTALS
HEALTH & SAFETY TOPICS
1. Health & Safety Policy
2. Health & Safety Plan
HEALTH & SAFETY
RESPONSIBILITY
3. General Health & Safety Rules
4. Health & Safety Procedures / Practices
5. Legal Obligations
6. Health & Safety Actions
MANAGEMENT
COMMITMENT
7. Health & Safety Communication
8. Management Support
9. Well-being of Employees
10. Health & Safety Orientation
EMPLOYEE
INVOLVEMENT
11. Employee Participation
12. Required Safe Practices
13. Identification of Hazards & Risks
HAZARD
&
RISK
MANAGEMENT
14. Control of Hazards & Risks
15. Hazard & Risk Reporting
16. Accident Reporting
17. Accident Investigation
18. Accident and Injury Analysis
19. Health & Safety Inspections
HEALTH & SAFETY
EDUCATION
20. Health & Safety Educational Needs
21. Health & Safety Education Delivery
22. Health & Safety Education Effectiveness
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1.
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Percentage of "Yes" Responce
We have seen results
Im perial Manufacturing Group : HSIS RESULTS
100.0
90.0
80.0
70.0
60.0
50.0
40.0
30.0
20.0
10.0
0.0
Health & Safety Topic
2002
2004
Imperial Sheet Metal Accident Frequency
compared to other companies in NB in metal industry
50.0
Frequency per 100 FTEs
45.0
40.0
35.0
30.0
25.0
20.0
15.0
10.0
5.0
97
98
99
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
FqAll - Imperial Sheet LTD. 47.06 48.04 51.55 27.14 21.82 28.25 14.24 11.98 5.73 6.32 9.6
28.84 31.5 35.77 19.64 13.44 14.56 10.76 11.88 9.73 9.44 11.1
FqAll - SIC 3049
9.8
9.6
9.4
9.4
The First Focus Department
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Through the accident analysis the department
with the highest number of accidents was
identified
Accident reduction teams developed in that
department
Meetings held bi-weekly and included
management, department employees from all
shifts ,maintenance and JHSC
Input encouraged from employees.
Action plan developed and communicated.
2002 Accident analysis
• Main focus was on the
Register department
• Two Hazards were identified within
this department
1.Cuts
2.soft tissue injuries
A glove supplier was consulted
Several types of gloves were identified that had
high cut protection
Glove trials were conducted and employees
were encouraged to give feedback
The proper gloves were purchased
Safe work practices were developed and
communicated – Yes employees were
required to wear the proper gloves
2003 there was 4 cuts a 80 % decrease
Soft Tissue injuries
In 2002 Register department had 11 back and 3
shoulder injuries
Accident reports were reviewed
Employees were encouraged to identify
problems and concerns
Work Safe ergonomic consultant assisted with
the process
Observations were done Hazards identified &
possible solutions discussed
• A Soft Tissue training power point was
developed and presented to all the employees
in the register department
• The training was to increase the employees
awareness of how the body worked, the
causes and how to prevent Soft tissue injuries
• With the group working together and
communication going out to all employees in
the department hazards were identified and
solutions were agreed upon
What was accomplished
through team work
• The weights that were carried to the
work stations was identified as a hazard
and employees are encouraged to
reduce the amount of product carried
(this is in the employees control)
• Tables with wheels were purchased to
transfer the material
Tilt bins were made that reduced the
need to bend to the floor
Cost $1500.00 each($12000.00 total)
Roller system was installed to reduce
push/pull force required on storage bins
Positive Results
2003
In the Register department
2 back & 1 shoulder injury
79% decrease
Accident reduction was seen
through out the facility
43% accident reduction seen throughout the
plant in 2003
Further reduction of 25% seen throughout the
plant in 2004
Employee Wellness/accident reduction
• Soft tissue injuries was identified as the
number one injury
• Outside company observed our production
process and developed a stretching exercise
program
• Exercise program initiated throughout the
production area
• Comfort surveys were completed & repeated 6
weeks after the program started - a decrease in
employee discomfort seen in several areas
Positive outcomes
Problem
Solution
Outcome
Increased costs
associated with
soft tissue
injuries of the
upper extremity
and low back
Implementation
of a job specific
exercise
program
Cost of program
development and
implementation:
August 1,2003 to
May 31,2004
August 1,2004 to
May 31,2005
Reduction of soft
tissue injuries =42%
Total of 24 Soft
tissue injuries
Lost time days =
211
Total of 14 Soft
tissue injuries
Lost time days =
54
Lost time days due to
soft tissue injuries
reduced by 74%
Total $595.00
Exercise Program
Cost of program development and
presentation = $595.00
Cost of 15 minute presentation and
demonstration to production employees
= $4000.00 ( wages and lost production)
Total lost $4595.00
Lost time days difference from
2004 & 2005 =156 days
What would be paid out by Work Safe
85% loss of earnings for 156 days = $13056.
Not taking into consideration Medical cost or lost production
cost savings is
$8461.
What does it mean to the employee that did
not get Injured
Priceless
Safety is priority when developing
new processes
Vibration & risk of soft tissue
identified
Equipment purchased to reduce
Hazards
Adjustable transport tables
Guarding was invented
Education & Awareness
• Soft tissue awareness training has been
given to all employees
• Understanding how soft tissue injuries
occur and how to prevent them is the key
• Earlier identification & employee
awareness is important
• With the right tools employees are able
to identify there is a problem & look for
solutions
This employee had wrist & elbow pain when
she had to test this particular unit that
required pinching, force & awkward posture
She informed the person who designed the
testing process & changes where made. The
employees satisfaction in solving this problem
can’t be measured
2010 H&S program highlights
Continued Management commitment!
Building on what we have.
Regular audits (5*22)
Improve RTW and Modified work programs
Improve accident reporting
Updated presentation given to all employees
Safety incentive program started
Other aspects of our Wellness
Program (H&S)
Nutritional awareness
Smoking cessation
Canada Fitweek Special events
First Aid Attendants appreciation
Blood Pressure Monitoring
Weight loss program (Weight Watchers at Work)
Ergonomic training
New emphasis on Exercises
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RESULTS OVER THE PAST 8 YEARS
The number and Severity of accidents
have decreased
Lost Time Days for 2002 = 1731
Lost Time Days for 2003 = 752
Lost Time Days for 2004 = 338
Lost Time Days for 2005 = 113
Lost Time Days for 2006 = 384
Lost Time Days for 2007 = 86
Lost Time Days for 2008 = 669
Lost Time Days for 2009 = 329
Safety is never ending !
IMG’s Goal is Zero accidents and
that everyone can go home safely
enjoying activities outside of work
IMG has seen dips in our progress
But our goal is continuous
improvements
Remember whether
at Work or at Home
“Take Time for Safety”
Questions ?