Healthy Workplaces Summit 2013 ‘ Working together for risk prevention’ STEP BY STEP SAFETY APPROACH TOFAŞ Safety and health at work is everyone’s concern. It’s good for you. It’s good for business.
Reaching Zero Accident Approach Injuries Management Self Team I N -Safety Captain -Teams Run Safety -Mandatory C -Employees Facilitate Meeting Process Compliance I -Safety Meetings -Teams Define Training -Safety Training -Snapshot Patrolling Required -Site and Unit Focus D -Training on Best -Dojo Safety on Rules and E -Practices -Dojo Ergonomics Procedures N -Employees in Incident -Teams Define and -Management Driven T -Investigations Complete Inspections Incident Investigations -Behavior Based Safety -Team Reward and -Risk Analysis Programs Recognition Focus -Management Audit R -Forum Theatre -Teams Define EH&S -Safety Patrol A -Employees Complete Goals -Safety Meetings Run T -Area Self-Inspections by Management E -Reward and -Management Defined Recognition Programs Goals and Reviews Technical Controls & -EHS Component in Applications / Audits All Goals and Reviews Culture Time Interdependent Dependent Independent ‘Zero by Choice’ ‘Zero is Unrealistic’ ‘Zero by Chance’ 2 www.healthy-workplaces.eu
Step by Step Safety Approach Approaches: Management Initiated Team initiated Self Initiated Model Areas STEP 7 AA Expansion Areas STEP 6 Fully Implemented A Expansion Areas Safety Standards STEP 5 Autonomous B-C Areas Safety Standards STEP 4 Autonomous Overall inspection of inspection safety levels STEP 3 Reevaluation if safety Predictive General control countermeasures Inspection for against safety Safety STEP 2 problems Train and grow Setting people in such a STEP 1 Tentative way that they Standards for care for safety Countermeasures Safety and Horizontal Expansion Listing all safety Analysis of problems Accidents Extension at similar areas Analysis of causes Reactive 3 Proactive Preventative www.healthy-workplaces.eu
Safety Management Audit &Training (SMAT) SINCE JAN-2009 WHY WE NEEDED? Showing commitment People get clear message To spread safety culture Being role model Follow up to correct problems or change behaviour Communication of results to employees FOR ALL MANAGEMENT LEVEL ‘‘3 don’t activities’’ such as; • Don’t overlook unsafe acts • Don’t compromise on execuses • Don’t ignore unsafe conditions UA IMPROVEMENT SMAT – REALIZED vs TARGET UC IMPROVEMENT 2012 Over the target.. 2012 Monthly Monthly Average Average 4 www.healthy-workplaces.eu
Safety Patrol WHY WE NEEDED? Management commitment Operators ’ motivation Emphasizing "safety first and a value Showing that “we care your safety" UC observations & coomunication with operators UC IMPROVEMENT METHOD -Once in two weeks at a random shopfloor -30 minutes duration -All management team 2012 -Workshop responsibles (related area leaders, safety specialist) participated... Monthly Average 5 www.healthy-workplaces.eu
Together with Trade Union Participation in weekly safety meeting Monthly safety committee Annual Safety Workshops Participation in Safety Management Audit &Training (SMAT) Near Miss, Accident Investigation Accompanying to worker during hospital treatment Participation in Safety Rewarding System 6 www.healthy-workplaces.eu
Safety Captain SINCE FEB-2010 NEED: *Workers have more eyes *To improve their awareness *To detect unsafe acts and conditions *To spread safety culture *For being autonomous and involvement *To enjoy and not create enemies Daily Meeting METHOD • One operator in every lean team becomes safety captain for a week • Responsible of his working area. • He doesn’t stop doing his own job. • Detects unsafe conditions and make them record into the database by his leaders. • Warns everybody who act unsafe and make recorded • into the system. • He does one SMAT audit for 15 minutes while his team leader working instead of him. He talks about his experiences; • Wears green hat & captain band during a week • How his friends react when he warn them. 7 www.healthy-workplaces.eu • His SMAT Audit, if there is UC, UA etc.
Snapshot Patrolling NEED Snapshot patrolling and exhibition of unsafe conditions, help making tangible improvement of the identified abnormality and horizontal expansion. METHOD : By all volunteered employees; • Unsafe Conditions; • Photographed • Location and time included • Mailed to plant safety team By Plant Safety Team; • Reported to related department • Followed up improvement and expansion We also focused on removing the perception that ‘‘Safety, is only the Safety Officer’s responsibility’’ 8 www.healthy-workplaces.eu
Hazard Prediction KIKEN YOCHI (Hazard Prediction) ONE MAN 4 ROUNDS SELF INITIATED TEAM INITIATED NEED - To ensure team initiated safety. - To improve danger prediction & defining NEED countermeasures skills Improving danger prediction skills of - Increases the motivation of workers to practice in operators related with non-routine works teams - To sharpen awareness of what causes dangers - To improve problem solving capabilities by working on finding solutions NON-ROUTINE WORKS Including; Including; • • Maintenance, Production, • • Logistics, Other operators. team members. STEP 5 STEP 6 9 www.healthy-workplaces.eu
Hazard Prediction – 4 Round HAZARD PREDICTION Strengthen risk prediction ONE MAN 4 ROUND skills&team initiated safety. Maintenance Production Units Logistic Lean Teams 3rd Round: Countermeasures decided by; STEP 5 STEP 6 -What would you do, if you were? 2nd Round: 1st Round: -What is the problem&what to do? Highlighted important dangers. Team members detected all Agreed ones re-circled again.. dangers by brain storming 4th Round: Defined team targets to 10 www.healthy-workplaces.eu eliminate the risk/danger
Team Flag SINCE MAY-2010 Lean Teams Lean Teams had accidents without accidents “hanged 3 months” We aimed to strengthen Team Initiated Concentration 11 www.healthy-workplaces.eu
Safety Simulation Training Areas 12 www.healthy-workplaces.eu
RESULTS 13 www.healthy-workplaces.eu
RESULTS 14 www.healthy-workplaces.eu
THANK YOU & HAVE SAFE WORKING DAYS 15 www.healthy-workplaces.eu
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