4 WAYS TO ACHIEVE THE NEXT LEVEL IN ENVIRONMENTAL, HEALTH AND SAFETY. Crown Equipment Corporation

Transcription

1 4 WAYS TO ACHIEVE THE NEXT LEVEL IN ENVIRONMENTAL, HEALTH AND SAFETY Tonja Rammel Manager of E, H, & S Brian Duffy Director of E, H, & S Crown Equipment Corporation

2 Introduction to Crown 5 regional headquarters 2.4 Billion USD FY ,700 employees 17 manufacturing plants in 11 locations worldwide Global line of trucks designed to local work practices Over 500 retail locations across 84 countries Innovative fleet management solutions Leader in material handling innovation and technology Family owned and managed since 1945 One of the World s Largest Lift Truck Manufacturers

3 Global Line of Lift Trucks Designed to meet local standards and operator preferences

4 Global Manufacturing 17 Manufacturing Plants in 11 Different Locations North America Manufacturing Plants New Bremen, Ohio (Corporate) Troy, OH Greencastle, IN New Castle, IN Kinston, NC Queretaro, Mexico

5 Vertical Integration Fabrication/Welding/ Heavy Machining Precision Machining Wire Harness Assembly Plant/ Distribution Center Motor Plant/Plastics Electronic Assembly Mast Plant

6 We would like to highlight 4 very successful, sustainable processes that we believe sustains our business by engaging our employees to move Crown to the next level in EH&S Crown Manufacturing Safety Incident Rates TCIR LWCIR 0

7 #1 - Safety Leadership Committees

8 History and Introduction Engage and empower employees to increase ownership of safety Continuous Improvement Individual Development Safety Leadership Committee Establishment Sub-Committee Establishment Leadership Development and Support

9 Development of the Safety Leadership Committees (SLC) Committee Member Selection Representation from all depts. & shifts People that are considered leaders Passionate about safety Willing to get involved

10 Examples of Safety Leadership Teams Safety Mentoring Team Eye Injury Prevention Team PPE Team Lockout/Tagout Team OSHA Compliance Teams Machine Move Team

11 Plant 3 Safety Organizational Chart Plant 3 Safety Organizational Chart Safety Specialist Plant 3 Safety Leadership Committee INJURY PREVENTION SAFESTEPS Regulatory Compliance Emergency Response Material Handling & Recyling Job Safety Analysis Team E. Grillot - 5 mbrs SafeSteps Steering Team K. Below/ B. Claybaugh - 11 members OSHA Compliance Team D. Voress- 16 mbrs CERT & MERT T. DeNise - 9 CERT / 6 MERT mbrs Lift Truck Operations B. Holdren - 6 mbrs New Hire Safety Sponsor C. Brown - 14 mbrs Drive Team K. Bell - 55 mbrs MSDS Team D. Thacker - 7 mbrs Fire Prevention Team D. Voress - 7 mbrs Machine Move Team R. Timmerman - 9 mbrs Trip Hazards Team M. Pendergraft - 13 mbrs Awareness Activities Team K. Below - 7 mbrs Hazardous Energy Team L. Fleckenstein - 13 mbrs Seasonal Safety Team D. Thacker - 14 mbrs Bolting StringersTeam R. Timmerman- 2 mbrs Ergonomic Audit Team M. Pendergraft - 11 mbrs Core Team Training B. Claybaugh mbrs Tool Inspection Team D. Thacker- 8 mbrs Hoist & Lift Attachment Team R. Timmerman - 5 mbrs Eye Safety Team NEED - 10 mbrs Hand Safety Team K. Bell - 13 mbrs Stretch Leaders R. Klenke - 25 mbrs Home Safety Team D. Behr - 5 mbrs Health & Wellness Team K. Below - 7 mbrs 195 Total People Involved/Volunteered Some participate on multiple teams 53% of Plant Involved

12 Safety Leadership Teams Effects on Plant Culture Eliminates injuries Increases plant engagement/ownership Promotes a positive safety culture Increases safe work habits Improves ergonomics and work conditions Exceeds OSHA compliance regulatory standards Communicates success stories within the plants

13 Common Safety Leadership Committee Questions How do you begin? What is the structure and support for a Safety Leadership Team? How does any production get done with so many employees participating on teams? Do some employees participate on multiple teams?

14 #2 -

15 History and Introduction Implemented SafeSteps in All NBO and GRN Mfg plants over last 10 years Presented SafeSteps to the 2011 AME Conference in Dallas Ohio Manufacturers Education Council, MAPI, Ohio BWC, SOSE and Many Customers Worked with Quality dept in Crown Mexico to implement the Behavioral Model in Quality

16 History and Introduction A process that attempts to change the way people behave Uses observations and feedback Uses positive reinforcement Builds habits Looks at behaviors not conditions Can improve workplace culture, productivity, quality as well as safety

17 SafeSteps Activity Arm Folding Exercise

18 How does it work? An employee based, informal peer to peer observation and feedback process using cards that contain the correct pinpointed behaviors. We want to catch folks doing the right things! We want to positively reinforce them when they do! We want them to run the process

19 How does it work? Plant Assessment Employee Run Steering Team Voluntary Anonymous Celebrations/Recognitions Pinpoint Cards Positive Feedback No Discipline

20 SafeSteps: A Behavioral Based Safety Process based on the ABC Behavioral Model Below

21 Antecedents: Things that Prompt Behaviors Safety Meetings Safety Training Warning Signs Instructions What do we do when these don t work? Remind Restate Retrain! Discipline!!

22 Consequences

23 Consequences

24 Why It Works: Immediate, Positive, Accurate Trusted Source

25 Why it Works The Power of Positive Reinforcement

26 Why It Works In a Manufacturing Setting It s all about employee engagement They become motivated They own it R+ Recognition Consequences Rooted in Behavioral Science, and what motivates people

27 #3 New Hire & Safety Mentoring

28 Background WHY did Crown change New Hire? THEN Day slides of OSHA requirements NOT focused on Injury Prevention 10-50% of New Hires are getting injured! NOW Focused on Hazard Recognition & Injury Prevention Focuses on Preventing Top 4 Crown Engaging, Interactive Demonstrated Performance Safety Mentoring w/positive Feedback Advancing Safety Culture

29 New Hire Process Day 1 Day 2 Weeks 1-5 HR & Safety Orientation Workplace Safety Orientation ** Safety Mentor Assigned to New Hire Hazard Recognition/Injury Prevention Modules Hand Injury Prevention Eye Injury Prevention Slips/Trips/Falls Prevention Strains Prevention

30 New Hire Process Hand Injury Prevention 1. Computer Based Module (CBT) - Self paced CBT - Interactive, Engaging - CBT is focused on - Hazard Recognition - Identifying Conditions and Behaviors - Injury Prevention - Integrated Quiz & Scenarios 2. Hands-On Training/Practice 3. Skill Check

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34 New Hire Process Hand Injury Prevention 1. Computer Based Module (CBT) - Self paced CBT - Interactive, Engaging - CBT is focused on - Hazard Recognition - Identifying Conditions/Behaviors - Injury Prevention - Integrated Quiz & Scenarios 2. Hands-On Training/Practice a) Hands-On Safety Training with Safety Mentor b) Complete Hands Practice Sheet - Identify Potential hand hazards in work area (while learning job) - Determine cause (condition and/or behavior) - Describe how to prevent the injury 3. Skill Check New Hire & Safety Mentor - Tell Me: New Hire discusses the 10 items from the Practice Sheet with Safety Mentor, explaining how conditions & behaviors can lead to hand injuries - Show Me: New Hire demonstrates their ability to prevent hand injuries to Safety Mentor. - No less than 100% is acceptable. Then repeat this same process for Eyes, Slips/Trips/Falls & Strains.

35 Feedback Positive feedback from Safety Mentors, New Hires & Supervisors: This style of orientation is hands-on, interactive and more personable. Taught us how to safely perform the everyday tasks, think about the little things Meeting new people, working one-on-one with safety mentor, forced me to talk with someone about safety and identifying the hazards myself was eye-opening, and having someone to go to with questions. Ability to guide/teach the new hire, and even learn a few things myself. Having a Safety Mentor really made me feel like Crown cares about me and my safety. The premise is awesome. This training is going to be effective and you will see the results. - New employees get the chance to recognize the hazards out on the shop floor. - There were some good finds in the skill checks. - I love the idea of having real world hands on training. - 1 on 1 mentoring instills more of a safety priority.

36 #4 - Environmental Sustainability

37 Our history as a sustainable company has been proven throughout the years: 1993: State of Ohio s Pollution Prevention Award 1994: Eliminated Solvent Degreasing 2003: USEPA National Waste Minimization Partner 2008: Ohio Award for Outstanding Achievement in Environmental Stewardship 2009: Zero Landfill Achievement 2010: ISO Achieved and Ohio Award for Outstanding Achievement in Environmental Stewardship 2011: Zero Landfill Achievement 2012: ISO Achieved 2014: Ohio EPA E3 Gold Status Award (NKO), Most Valuable Pollution Prevention Award (MVP2), Hosted Zero Waste to Landfill Workshop 2015: Ohio EPA E3 Gold Status Award - Plt 7

38 Sustaining and Promoting Environmental Engagement Environmental Sustainability Events Zero Waste to Landfill ISO 14001

39 Environmental Sustainability Events Environmental Sustainability Team Events Lean, Green and Safety

40 Zero Waste to Landfill Benefits Rethink, Recycle, Reuse, and Reduce Challenges

41 ISO Benefits Date Senior Management NKO Envir onment al Commitment Car ds Environmental Policy Development Management Review Put Recycling in correct container Turn off lights when leaving Use hand dryers when possible Turn off machine when not in use Feedback Yes NO Given Total Regulatory and third party registrar support Ohio EPA Office of Compliance Assistance and Pollution Prevention Challenges

42 In Summary In order to improve your EHS processes and get to the next level Engaging employees in Safety and Environmental is key. Their ownership can provide the company with significant performance improvements. Crown has had excellent success with these four approaches. Do not hesitate to contact us for further information

43 Thank You! Please complete the session survey at: Session: WP/29 4 Ways to Achieve the Next Level in Environmental, Health and Safety Brian Duffy / Tonja Rammel Crown Equipment Corporation Brian.Duffy@crown.com Tonja.Rammel@crown.com