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Creating a Accident Free Work Environment

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  1. Creating a Accident Free Work Environment Why Not Set Your Goal to ZERO! Presented By: Betty Knox

  2. The Swiss Colony Defining Zero Accidents Measuring Safety Performance Creating a Zero Accident Program Agenda

  3. Facilities 13 Cities Madison Dickeyville Monroe Peosta Janesville DeWitt Oak Brook Davenport Savanna Clinton Hannibal Reno, Nevada Shanghai, China

  4. 12 Jets 22 Pilots

  5. Many may look at Zero and think it is not possible. Setting the Goal at Zero is setting us up for failure. If we say that zero injuries is not possible, then how many injuries are acceptable each year, and what type of injuries are acceptable? Is it OK if we have only one injury during the year, but what if the result is a serious injury of an employee or life altering event? Is Zero Accident Possible?

  6. Your company goes through stretches of time when you have zero safety incidents. Safe minutes add up to safe hours, and safe hours to days, and so on and so on. From a workers standpoint, zero is the only supportable goal Any other goal leaves the subtle message that injuries will occur and that injuries are acceptable Zero Accidents Why Not Aim For Zero!

  7. Most Companies define zero accidents to mean “Zero Lost-Time Accidents” which is a worthy goal. Maintenance Department 21 Years No Lost Time Mailing Print Shop 17 Years No Lost Time Bakery Achieved 1 Millions Hours No Lost Time Defining Zero Accidents to mean “All Accidents" regardless of severity and type, is a worthier goal. 9 Departments Achieved Zero Accidents 2009 12 Departments are at Zero today! Defining Zero Accidents

  8. Employee Perception of Safety Where is your Company now in safety performance? Measuring the Safety Management System Measuring Safety Performance

  9. Under-reporting , Over-reporting Injury rates often do not reflect the potential severity of an event, merely the consequence For example, the same failing to adequately guard a machine could result in a cut finger or an amputation A low injury rate can lead to complacency We experienced this between 2005 - 2007 Injury statistics reflect outcomes not causes Injury statistics can give you a false indication of your overall safety performance. Problems with Statistics

  10. We need to be measuring the Presence of Safety rather than the absence of injury Measure the safety process within your facility How well is the safety process running? How do you identify successes and failures? Do you allow for the process to be adjusted or improved before incidents occur? Measuring Performance

  11. Measuring safety performance first requires you to define what is safety performance. Is it prevention of injury or harm? Is it defining actions plans or accomplishments to include preventing injury or harm in the workplace? Is it defining individual safety performance? Measuring performance fits within our overall safety management system and is a key factor in creating our Zero Accident Program. Measuring Safety Performance

  12. Measuring Performance Initial Hazard ID/RTW Efforts First Aid Contact Log Introduced Safety Accountability Implemented Incentives OSHA Compliance Capital Expenditures Comprehensive Safety Audit Safety Awareness LOTO /Equipment Hazard Assessments Train the Trainers Accountability Training De-Centralized Safety Function Revised Fork lift Target Zero

  13. Measuring - Audit Results

  14. Measuring Against Industry Data Collected from Bureau of Labor Statistics NAICS Code 3119

  15. Measuring your Safety Management System SMS can be defined as a coordinated, comprehensive set of processes designed to direct and control resources to optimally manage safety. SMS takes unrelated processes and builds them into one coherent structure to achieve a higher level of safety performance, making safety management an integral part of overall risk management. SMS is based on leadership and accountability. It requires proactive hazard identification, risk management, information control, auditing and training. It also includes incident/accident investigation and analysis. Safety Management System (SMS)

  16. Our Safety Management System key elements: Safety Management System • Leadership & Accountability • Policies and Objectives • Organization and Resources • Hazard Risk / Control Management • Design and Pre-Planning • Implementation and Monitoring • Assessment and Continuous Improvement • Measuring Performance

  17. Safety Management System Flow Chart Safety System Flow Chart Information link Control Link Policy Policy Development Organizing Organizational Development Auditing Planning and Implementing Developing Techniques Planning, Measuring, Reviewing, Monitoring Measuring Performance Reviewing Performance Feedback Loop to Improve Performance

  18. Just like finance, production or sales, you need to measure your safety performance to find out if you are being successful. You need to know: where you are; where you want to be; what is the difference - and why Active monitoring, before things go wrong, involves regular inspection and checking to ensure that your standards are being implemented and management controls are working Reactive monitoring, after things go wrong, involves learning from your mistakes, whether they have resulted in injuries and illness property damage or near misses Measuring Safety Performance

  19. Where are we now relative to our overall safety? Where are we now in controlling hazards and risks? How do we compare, Are we getting better or worse? Is an effective safety management system in place across all parts of the organization (deployment)? Is our culture supportive of safety, particularly in the face of competing demands? Prior to Implementation we Asked • Are we succeeding in eliminating or reducing hazards? • Are we ready for Zero Accident Program? YES!

  20. Creating Zero Accident Program

  21. Changing the Perception of Safety Making a impact on our Seasonal Temporary Workforce (~5500) Impacting our Diverse Workgroup Additional Resources in Safety Some of the Challenges

  22. Gap Analysis Safety Management System. Implement Corrective Action Plan for identified gaps Assigned Responsibilities and Timelines Employee Survey Results Safety Awareness Survey Human Resources Employee Survey Employee Interviews Statistical Data Accident Trends Near Miss Reports Comprehensive Audit Results BLS Statistics Setting and Reviewing Goals Communicate the Zero Accident Goal. Everyone must be on the same page and understand that this really is not an unreachable goal. Preparing for Zero Accident Plan

  23. Employee Perception Survey

  24. Auditing the Elements

  25. Setting Goals

  26. Safety Action Plans. Developed and Implemented Site Specific Safety Action Plans to define safety initiatives. Safety Accountability Program Revised current program Identified Gap in Training Identified Target Group for Additional training Commitment Comprehensive Safety Audit Revised current audit format Developed and Implemented Training Safety Training Revised training format Train the Trainer Certification Communicate the Zero Accident Goal. Everyone must be on the same page and understand that this really is not an unreachable goal. Preparing for Zero Accident Plan

  27. Accountability / Incident Rate Review

  28. Safety Accountability

  29. Establishing Safety Committees Executive Safety Team Corporate Safety Action Committee Departmental Safety Committee (21) Safety Committee Roles and Responsibilities Training Accident Investigation Accident Investigation Training Revised Return to Work Program Developed Accident Summary for treating Physicians Near Miss Reporting and Trending Document Control Program Developed a New Policy / Procedure Guideline Implemented a new review process Formed a Policy Review Committee Master File Intranet Based Preparing for Zero Accident Plan

  30. Employee Involvement Management Commitment Accident Analysis Accountability Hazard Identification Awareness Training Key Components Elements To Achieving Zero Accidents

  31. Identified the Elements • Management Commitment • Management of our company shows, in words and actions, their commitment to our safety and health program. • Accountability • Responsibilities and authority are assigned. • All employees (including management) are held accountable • Facility Safety Action Plans define the roles, responsibility and accountability to each element. • Hazard Identification and Control • Monthly Hazard Assessment Audits • Pre – Job Planning and Equipment Approval Process • Incident/Accident Analysis • Procedures and policies are in place for reviewing all workplace near miss incidents, accidents, injuries and illnesses.

  32. Communication and Awareness Promote Safety Initiatives Open Line of Communication Safety Training There is a comprehensive training program all employees Employee Involvement Employees are encouraged to, and actively participate in the development and implementation of our safety programs Program Evaluation Facility Program Audits, facility will conduct Quarterly Audit Annual Comprehensive Safety Audit. Identified the Elements

  33. Corporate Annual Communication Meeting President / CEO Announced New Program July 2009 Zero Candy Bars Distributed for Kick-Off Corporate Mission Statement Signed by all Executives and Displayed in every Facilities Target Zero Communication Plan Colony Contact Internal News Letter Mass E-Mail from the President CEO Banners, Flyers, Safety Talks 2010 Target Zero Calendar Target Zero Accident Program Incentive Plan Corporate Target Zero Incentive Target Zero Group Incentive Safety Day Incentive Introduction of Target Zero

  34. Phase 1: Management Commitment Facility Management Commitment Plan to Target Zero Each facility to develop a Commitment plan Target Zero Facility Commitment Implementation Plan Each facility to develop a plan on how they will implement the plan Accountability Roles and Responsibilities defined for all employees & posted Safety Disciplinary Policy Revised and Communicated All Managers are required to attend General Safety Accountability Training. Departmental Safety Action Plans to include Accountability Target Zero Implementation Plan

  35. Phase 2: Hazard Identification and Control Hazard Recognition Training Pre-Job Planning Process Equipment Approval Process Safety Department Monthly Site Visits Strain Index Studies for all High Risk Areas Risk Assessments' – update all JSA and JHA Hazard Reporting Safety Observation Program Idea Generator Near Miss Reporting Safety Department E-Mail System Target Zero Implementation Plan

  36. Phase 2: Accident Investigation and Reporting Accident Investigation Root Analysis Training Mock Drill Training Early Reporting Requirements Disciplinary Action for Failure to Report Accident Prevention Accident Prevention Awareness Training Stretch and Flex Program Wellness Program Health Risk Assessments' Target Zero Implementation Plan

  37. Phase 3: Communication and Awareness Safety Bulletin Board Employee Annual Safety Meeting Weekly Safety Communication Talk Monthly Safety Review Update on Safety Day 12 Monthly Required Safety Talk Safety Training Target Zero – Zero Accident Program Training New Safety Orientation to include Zero Accident Program Safety Compliance Training Safety Training Site Specific Train the Trainers Certification Re-alignment of Training Frequency Target Zero Implementation Plan

  38. Phase 4: Target Zero Implementation Plan • Employee Involvement • Employee Participation • Employee Annual Compliance Training • Employee Monthly Safety Activities • Employee Involvement in Safety Day Activities • Safety Committee • Program Evaluation • Annual Safety Comprehensive Audit • Review Target Zero Impact • Review Department Safety Action Plan

  39. Promoting Target Zero

  40. 1 Month 3 Month Grand Prize 1 Year 9 Months 6 Months ASK How You Can Win One Of These Prizes! Target Zero Group Incentive Safety Day Awareness Incentive Corporate Safety Incentive I-month 5 2-months 5 3-months 10 4-months 5 5-months 5 6-months 20 7-months 5 8-months 5 9-months 25 10-months 5 11-months 5 I Year 50 Earn Booster Discount Certificates For Each Month the Corporation is accident free. No pay out when an accident occurs for that month. The clock starts over at five booster discount certificates . 3rd Wednesday of each Month, Turn in your monthly quiz for a chance to hit the target for one of these prizes. Hit the bulls-eye and receive 25 additional booster discount certificates. • To be eligible for the departmental random drawing your assigned Target Group • Must Have: • 100% Employee Participation in Monthly Quizzes • Zero Accidents for Each Milestone Period. Accident Prevention! Our Intention is...

  41. Assigns Authority and Accountability Ensures Compliancewith all safety rules Establishes two-way Communication Provides for Periodic safety inspections Requires Investigation of Accidents & Injuries Corrects hazards when observed or discovered Specifiesgeneral & job-specific safety training Maintains Inspection & Training Records Demonstrates Commitment Benefits of a Zero Accident Plan

  42. “Thank-you” The only goal that represents the intended results of an effective safety program is Zero Accidents. It makes sense from a moral, economic, and safety standpoint. It says accidents are unacceptable and preventable. Make it your company's goals It's all about expectations!