HasnainMerchant. Reduction in LWD Due to Lacerations

Transcription

1 HasnainMerchant Reduction in LWD Due to Lacerations

2 Lake Mills, IA Filtration Key Objectives Have Speed Everything Speaks Use VPI World Class Materials Everything Moves Quality In All That 6. We Do 7. Take Care Of Our Customers Efficiency In Our 5. Operations Take Care Of Our People 1. Everything Fits 1

3 Reduce Number of Lacerations Reported per Month Objective: Benefits: Team: Schedule: Reduce/optimize/increase Near/ Misses for Lacerations (project y) from 4.41 (current level) to 2.2 (good level) for Lake Mills, IA plant (specific area) while reducing/increasing/holding constant while maintaining productivity, quality, employee morale and safety standards (constraining Y s) Decrease in number of near misses due to lacerations will result in fewer OSHA related incidents which will result in fewer LWD incidents hence resulting in savings Belt: Hasnain Merchant Sponsor: Aurelio Ramirez Controller: Kimberly Valentine MBB: Patrick Rohn Team members: Darin Hagen, Donald W Peterson, Phillip E Rice, Becky A Avelar, Jason M Chose Project Start: 02/15/09 Improve: 3/17/09 Measure: 03/10/08 Control: 6/12/09 Analyze: 03/17/09 Closeout: 6/1709 3

4 Process Map (5K) People Tool PPE Rushed Incorrect Tools No PPE Tuking shortcut Wornout Tool Inadequate PPE Training (Y/N) No Tool Worn out PPE Lack use of tools Position Availabity of PPE Lack of use of PPE Usege of tool Stals correct Poor judgement Illegal tools Lack of caution Drowsiress No specific procedure Machine grardown Incorrect Material Worn out carries Lacerations Puntures Avulsions Skipping steps in daily process Machine design Incorrect staging Sharp edges Splinters Lack of guarding On the floor Layout Improper guarding Staging On the pallet Mal funtion Abnormal situation Splinter Accessibility Y/N Maintenance Methods & Process Equipment Material Material Handling 4

5 Capability/Baseline Study I-MR Chart of Num of Misses 15 UCL=13.85 Individual Value _ X=4.42 Month Quarter Q Q Q Q Q Q2-2008Q Q Q3-2008Q LC L= Q Q UCL=11.58 Moving Range MR=3.55 Month Quarter Q Q Q Q Q Q2-2008Q Q Q3-2008Q LCL= Q Q

6 Multi-vari Study Analyze Phase Summary y = f ( x 1, x 2,, x k ) y x 1 x 2 x 3 x 4 x 5 = Count of Incidents = Machine Guarding = Operator Alertness = Part of Body = PPE Inadequate = Abnormal Operation 6

7 Improvements Implemented 7 Daily Start up meeting with safety talks by Safety Point Leaders, (Jan-09) Weekly Safety topic and/or Safety video. Plant safety STOP for all OSHA recordables (Jan-09) New Safety Audit and 5S Audit Checklist per department and shift (Jan-09) Everyone in plant including SPL were trained, Monthly Safety and 5S Audit by SPL, Weekly review by SPL meeting, New Safety Scorecards and Ergo Scorecards (Jan-09) Many Safety and Ergo projects was identified. Weekly Management Review of scorecard and top 3 safety projects for 3 departments on a 6 week cycle Safety Point Leader* (~45) (Feb-09) They were trained in many safety topics: Machine guarding, PPE requirements, Safety Audit, ergonomics etc *The role is to identify and eliminate hazards, raise awareness of safety and provide the input to team members regarding working safely. This is key role to achieving a World Class right environment for all of us. PPE requirement survey developed and being conducted in plant

8 Improvements Implemented, Continued 200 Safety CARS opened and closed about 140 so far. (4 maintenance technicians dedicated full time for safety CAR s) (Jan-09) All the not approved knives, these was removed of the areas. (Feb-09) Job Safety Analysis to: Safety Analysis for machine guarding in both plants (May-09) Safety Analysis for PPE requirements in both plants (May-09) Safety Analysis for Hand and Portable Power Tools (May-09) Machine Guarding Training (April-009) For maintenance group For SPL PPE Manual Update Visual Update on line by area (June -09) 8

9 9 Safety Scorecard Plant Level and by Dept

10 Visual PPE Tool on Shop Floor JOB SAFETY AND SEQUENCE INSTRUCTION DEPARTMENT: 22 Asset # Reviewed By: HSE Manager AREA: Front Task Description 1 Cutoff 2 Clippers N/A Date Reviewed: Jun 2009 Symbol Task Protective Measures 1 to 8 Safety Glasses 3 Centertubes 4 Rubberbands 5 1st Assembly 6 Coater 7 2nd Assembly Inside 8 2nd assembly Outside 3,5,6,7,8 3,5,6,7,8 7,8 Best Cut Resistant Hy-Flex Best Cut Resistant- Kevlar Zorbit 4560 Dupont Protective White Sleeve 7,8 Denim Apron No Pockets when wearing shorts All Ergo requirements All Job Rotation: W/ ALL EHS Expectations 1. Always wear the correct PPE for the job you are doing 2. Maintain housekeeping in your work area 3. Report injuries immediately to your RTL or SPL Team member. 4. Report unsafe conditions immediately 5. Know & follow the SOP's rules and Safety Procedures SPECIAL INSTRUCTIONS AVOID TWISTING PIVOT FEET KEEP WORK AREA CLEAN 10

11 11 Project Team

12 Safety CR s Activity Work Orders Safety Audit 04 (Quarterly) Safety Point Leader Audit 0 Mar'08 Apr'08 May'08 Jun'08 Jul'08 Aug'08 Sep'08 Oct '08 Nov'08 Dic'08 Jan'09 Feb'09 Mar'09 Apr'09 New Closed Open

13 Final Control Chart Before After Improvements I Chart of Num of Misses by Quarter 20 Q Q Q Q Q Q Individual Value UCL=7.32 _ X=2-5 LCL=-3.32 Month Quarter Q Q Q Q Q Q Q Q Q