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Lean Safety : Transforming your Safety Culture with Lean Management PDF

188 Pages·2009·1.13 MB·English
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LEAN SAFETY Transforming Your Safety Culture with Lean Management LEAN SAFETY Transforming Your Safety Culture with Lean Management Robert B. Hafey CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2009 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S. Government works Version Date: 20131121 International Standard Book Number-13: 978-1-4398-1643-1 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid- ity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or uti- lized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopy- ing, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright.com (http:// www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com Dedication To everyone who works with their hands and attempts to stay out of harm’s way. Stay safe. Writing a book provided me the challenge of setting my own course—seek- ing personal growth rather than security. Without the unconditional love and support of my bride of many years, Sandy, this would have been an impos- sible task. Thank you for a lifetime of understanding. Contents Acknowledgments ............................................................................ xi Introduction ................................................................................... xiii 1 Why Focus on Safety? ..................................................................1 Demonstrate That Safety Really Is First .....................................................1 Quick Guide: Lean Focused Approach to Safety Management .................7 Endnotes ......................................................................................................8 2 Change the Culture ......................................................................9 A Common Goal of Both Lean Philosophy and Safety Programs ............9 Quick Guide: Change the Culture ............................................................13 3 Leadership’s Role .......................................................................15 Focus Everyone on the Process................................................................15 Quick Guide: Leadership’s Role ................................................................24 4 Lean Tools for Safety .................................................................25 You Can Continuously Cope or You Can Continuously Improve— The Choice Is Yours ..................................................................................25 Lean Tool 5S: A Structured Method of Workplace Organization ....27 Sort .............................................................................................28 Set in Order ...............................................................................28 Shine ..........................................................................................29 Standardize ................................................................................30 Sustain ........................................................................................31 Disciplined Approach Necessary to Maintain Safety in the Workplace ..........................................................................................32 Lean Tool: Visual Factory ..................................................................34 Signage .......................................................................................34 Charts .........................................................................................36 vii viii  ◾  Contents Signaling Systems ....................................................................... 36 Process Mapping ........................................................................ 37 Lean Tool: Training ........................................................................... 37 Lean Tool: Poka-Yoke (Failsafe) ........................................................ 39 Lean Tool: Benchmarking ................................................................. 40 Lean Tool: Continuous Flow/Cycle Time Gains ............................... 41 Lean Tool: Standard Work ................................................................. 43 Lean Tool: Problem Solving .............................................................. 45 Lean Tool: Metrics ............................................................................. 48 Lean Tool: Teams .............................................................................. 49 Quick Guide: Lean Tools for Safety ......................................................... 51 Endnotes ....................................................................................................52 5 Advanced Lean Tools for Safety ................................................53 Facilitated Leadership: Changing How People Think .............................53 Lean Tool: A3 Problem Solving ........................................................53 Step 1: State the Agreed Upon Problem or Need .....................54 Step 2: Draw the Current State Map or State the Current Condition ...................................................................................54 Step 3: Problem Solving—Use Ask “Why” Five Times Technique to Get to Root Causes .............................................54 Step 4: The Future State—Draw a Map or Describe How You Would Like It to Be ............................................................57 Step 5: Implementation Plan .....................................................57 Step 6: Audit Expected Results against Actual Results .............57 Lean Tool: Kaizen Blitz .....................................................................58 Planning the Kaizen Event ........................................................61 Facilitating the Kaizen Blitz .......................................................68 Kaizen Team Presentation .........................................................78 Kaizen Event Follow-Up Meeting ..............................................80 Quick Guide: Advanced Lean Tools for Safety ........................................91 Endnote .....................................................................................................91 6 Safety Program Leadership .......................................................93 It Doesn’t Have to Be a Manager .............................................................93 Team Leader ......................................................................................95 Management Facilitator .....................................................................95 Accident Investigation Facilitator ......................................................95 Recorder Keeper ................................................................................96 Subteam Leaders ................................................................................96 Contents  ◾  ix Human Resources (HR) Facilitator .................................................... 99 Safety Walk Co-Coordinator ............................................................. 99 OSHA Knowledge Expert ................................................................. 99 Training Coordinator ....................................................................... 100 Quick Guide: Safety Program Leadership ..............................................102 Endnote ...................................................................................................103 7 Incident/Accident Investigation ...............................................105 Getting to Root Causes and Lasting Solutions .......................................105 Focus on Process, Not People ................................................................106 Getting to Root Cause and Corrective Actions ......................................108 Quick Guide: Lean Approach to Incident and Accident Investigations .... 112 8 Promoting Safety .....................................................................113 Engaging Employees to Build Safety Awareness ................................... 113 Flash Meetings ................................................................................. 114 Benchmarking (A Standard against Which Something Can Be Measured or Assessed).................................................................... 114 Safety Improvement Programs ........................................................ 116 Safety Observation Program ........................................................... 117 Job Safety Analysis .......................................................................... 119 Safety Kaizen Blitz Events ....................................................... 119 Quick Guide: Lean Approach to Internal Safety Promotion .................120 9 Roadmap to World-Class Safety ...............................................121 Pulling the Pieces Together to Build or Rebuild a Safety Program .......121 Safety Program Leadership .............................................................122 Lean Approach to Safety Program Leadership ...............................122 Safety Team ..............................................................................122 Lean Approach to a Safety Team ............................................123 Other Team Building Opportunities ...............................................124 Recordkeeping .................................................................................126 Lean Approach to Recordkeeping ..................................................126 Safety Program Outline Documents .......................................127 Safety Education ..............................................................................127 Lean Approach to Safety Education ................................................128 Safety Program Activity Management .............................................129 Lean Approach to Safety Program Activity Management .......129 Safety Rule Defnition ..................................................................... 131 Lean Approach to Safety Rule Defnition ............................... 131

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