Lean Safety : Transforming your Safety Culture with Lean Management

188 Pages·2009·1.13 MB·English

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
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Boca Raton, FL 33487-2742
© 2009 by Taylor & Francis Group, LLC
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Version Date: 20131121
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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