Approaches for Staying at Forefront of Worker Safety Paul Schaum, COO Pretzels, Inc Chair; OpX Worker Safety Solutions Group

Transcription

1 SEPTEMBER 25, 2017 Approaches for Staying at Forefront of Worker Safety Paul Schaum, COO Pretzels, Inc Chair; OpX Worker Safety Solutions Group 1

2 AGENDA 1. Introduction to PMMI s OpX Leadership Network 2. Worker Safety Solutions Group Description of Opportunity Objectives Tools in Development Q & A

3 MOVING OPERATIONAL EXCELLENCE FORWARD community of Manufacturing, Engineering & Operations professionals Over 250 companies on solving common operational challenges Develop best practices and protocols for industry PMMI FOUNDED OpX LEADERSHIP NETWORK in 2011

4 BEST PRACTICES FOR INDUSTRY, BY INDUSTRY

5 NEW PUBLICATIONS IN PIPELINE Plan for Fall - Winter 2017 Peer Review & Pilots Release Publication Innovation Stage at PELV Webinar - Pro Food World CIP September October Wednesday 9.27 Worker Safety October November Monday 9.25 Secured Vendor January February October 26 RFP November December Tuesday

6 THE NEED TO DRIVE TO ZERO 2013 TRIR World Class All Manufacturing (21 categories) TRIR Food & Beverage (#2) The good news in workplace injuries and fatalities in general and in food and beverage manufacturing in particular is that rates are continuing a slow, steady decline. The bad news is that 46 food workers died last year, according to the Bureau of Labor Statistics, and another 76,900 food, beverage and tobacco workers were injured seriously enough to require time away from work. Cultivating a Culture of Safety in Food and Beverage Plants By Kevin T. Higgins, Managing Editor Oct 06,

7 THE NEED TO DRIVE TO ZERO More data 370,000,000 on worker safety Thousands of pages 24% 42% 37% 60% 24% of food workers have been injured at their current job, and 17% of workers were injured in their first year. 42% of workers rarely or never receive coaching from their manager or supervisor, and 20% said they received too little training before starting their job. 37% of workers and 43% of supervisors agree that training is sometimes too complicated or difficult to understand. Food manufacturing workers have a 60% higher rate of occupational injury and illness than workers in other industries. The risk of occupational death is 9.5 times higher for food industry workers than in non-food jobs. Source: Antea Group study

8 STRATEGIC OBJECTIVE: DRIVE TO ZERO To assist CPGs and their OEMs and other suppliers in implementing best practices to mitigate conditional (equipment, line configuration, materials and environment) and behavioral (thinking, acting, choosing and deciding) risks related to worker safety. Worker Safety Solutions Group Abbott Amway Baxter Bumble Bee Foods H-E-B JM Smucker Land O' Frost Land O' Lakes Mettler Toledo MGS Machine Natures Bounty Nestle Pressed Juicery Pretzels, Inc RA Jones SMC Sugar - Creek Whitewave Wornick Foods

9 TOOLS IN DEVELOPMENT WORKER SAFETY READINESS SURVEY Key Perspectives from the workforce Commitment to a Culture of Safety Leadership & Equipment Commitment to a Safety Plan Leadership & Equipment 9

10 10

11 CULTURE OF SAFETY- SURVEY AND GUIDANCE Leadership (Behavioral) Guidance Equipment Safety (Conditional) Guidance Leaders at all levels in our company are committed to developing and sustaining a culture of safety throughout the company. Leadership in our company ensures that the right amounts of resources especially human and financial resources are put in place to support a successful culture of safety Best systems have buy-in from the top; desire for leadership at all levels to be more proactive need to set the tone of the culture - say/do disconnect needs to change safety top priority at all times, not after an incident Open and transparent communication allows associates the information needed to make effective decisions with regards to value added application of time and funding. (see OpX Workforce Engagement) Our company is keenly aware of and addresses the leading worker safety risks, especially as they relate to equipment. Our company has a steadfast adherence to industry equipment standards relative to our manufacturing processes, e.g. ANSI/PMMI B155.1 Company awareness and adherence to standards for worker safety PMMI risk assessment for equipment and the end user. Safe design, safeguarding and safe use of equipment viewed as a lifetime risk assessment, Roles and responsibilities in integration of different pieces of equipment, 11

12 COMMITMENT TO A SAFETY PLAN - SURVEY AND GUIDANCE Leadership (Behavioral) Guidance Equipment Safety (Conditional) Conditional Leadership has seen to it that we have a comprehensive safety plan in place in our company. There is a tight link between the metrics in our safety plan and the awareness program for everyone in our organization. Best in class; Autonomous Safety... There is a dedicated safety professional at the site They are the subject matter expert that enables safety to flourish Front line associates own the safety at line: e.g. fork lift drivers as SMEs for fork lift safety, a line operator as the SME for the line Create greater awareness and incentives for safety; Focus on leading indicators, but not on lagging indicators Supervisors/managers bonus program related to reduction in incidences, Expectations regarding worker safety are clearly communicated and well understood by all workers. Anyone in the company has the authority to stop production if a serious safety condition is found to exist. Clarity and Understanding of expectations by each worker Leadership must use the principles and values of the organization to provide the associates and teams with guidance for decision making. Leadership should use the concept of smart trust. (see OpX Workforce Engagement) 12

13 DRILL DOWN AREAS - SURVEY AND GUIDANCE Electrical Electrical Safety is an integral part of our Safety Program We have a well-developed Arc Flash Training and awareness program for our employees; Training is monitored and tracked Awareness of Arc flashes incidents Ammonia There is a dedicated person responsible for managing the PSM program There is a robust PM maintenance program in place for the ammonia system Machine Safeguarding Our company has a written Machine Safeguarding Program that is maintained at the facility and is available to employees to review Our company requires start-up procedures to include Machine Safeguarding inspections

14 SEPTEMBER 25, 2017 Approaches for Staying at Forefront of Worker Safety Q&A Paul Schaum, COO, Pretzels, Inc More Info: Opxleadershipnetwork.org 14