Putting Performance in the Hands of Your People

Improving Your Safety Culture

Introducing

Monchello Curry, PMP, SMC

Learning Lead

Workforce Development and Training

• Introduction to Safety Culture▪ Case Study

• Define Safety Culture▪ Hands-On Activity

• Define World Class Organizational Safety Culture▪ Hands-On Activity

• Develop a Safety Culture▪ Prevention

• Hands-On Activity

▪ Capability• Hands-On Activity

▪ Compliance

▪ Case Study• Hands-On Activity

• Q&A

Agenda

Thank you. Introduction to Safety Culture

Case Study: Auto Parts Manufacturing Corp (APM)

The Good

Case Study: Auto Parts Manufacturing Corp (APM)

The Bad▪ Majority Temp Workers

▪ High Severe Incident Rate

▪ Incomplete Safety Manual

▪ Inadequate Training

▪ High Turnover

• The Ugly

▪ Lack of training

▪ No fall protection for employees climbing >12ft high

▪ Inadequate machine guarding/anchoring

▪ No records of equipment inspections

▪ Unlabeled containers

▪ Outdated Safety Data Sheets (SDS)

▪ Lack of appropriate PPE

Case Study: Auto Parts Manufacturing Corp (APM)

Thank you. Safety Culture Defined

Safety culture is a measurement of company and worker behavior, attitude, beliefs, perceptions and values that employees share in relation to safety in the workplace.

Safety Culture Defined

• Employers are advised and encouraged to institute and maintain in their establishments a program that provides adequate systematic policies, procedures, and practices to protect their employees from, and allow them to recognize, job-related safety and health hazards.

• An effective program includes provisions for the systematic identification, evaluation, and prevention or control of general workplace hazards, specific job hazards, and potential hazards that may arise from foreseeableconditions.

OSHA’s Definition

1926 Subpart C, Safety and Health Program Management Guidelines

The extent to which the program is described in

writing is less important than how effective it is in

practice.

• Management Commitment and Employee Involvement

• Worksite Analysis

• Hazard Prevention and Control

• Safety and Health Training

OSHA’s Elements of Safety Program

From OSHA Safety Program to World Class Safety Culture

Management Commitment and Employee Involvement

Worksite Analysis

Hazard Prevention and Control

Safety and Health

Training

• Vision / Mission

• Principles

• Safety Committee

• Compliance

▪ Rules

▪ Regulations

▪ Audits

▪ Scorecards

• Prevention

▪ Policies

▪ Goals

▪ Hazard

Control

• Capability

▪ Passive

Engagement

▪ Pro-Active

Engagement

▪ Integrated

Engagement

World Class Safety Culture Components

World Class Safety Culture

Policies

Goals

Hazard

Control

Passive

Engagement

Proactive

EngagementBest

PracticesIntegrated

Engagement

Audits

Scorecards

SafetyProgram

Vision / Mission

Principles

Safety Committee

Polytron, Inc. 2017

• Vision/Mission• Principles• Safety Committee• Safety Program – Engagement Rules

▪ Prevention• Policies, Goals, Hazard Control

▪ Capability• Passive & Pro-Active Training• Integrated Safety Activities &

Award System

▪ Compliance• Rules, Regulations, Scorecards

World Class Safety Culture

Vision / Mission

Principles

Safety Committee

SafetyProgram

Polytron, Inc. 2017

Safety Culture Starts With Vision/Mission

We are committed to providing

a safe and healthy workplace

for our employees …

We will provide the leadership

necessary to create a culture

in which all employees accept

personal responsibility for

workplace safety & health.

We have the right to work in

a safe environment.

Our vision is to have every

colleague, contractor and visitor

return home safely at the end of

each day.

You get the level of safety performance

and excellence that you, as a leader,

personally demonstrate you want.

Guiding Safety Principles

Safety Culture continues by establishing principles to guide leadership, employee,

visitor and contractor behavior.

• Work is never so urgent that we cannot take time to do it safely.

• Everyone is obligated to raise concerns about hazards.

• Everyone is responsible for speaking up when they observe a person performing at-risk behavior.

• All supervisory levels are accountable for safety performance.

• You must demonstrate alignment to the safety mission in both words and actions.

Guiding Safety Principles

• Primary purpose – to promote safety awareness and reduce probable injury/loss.

• General functions include:▪ Support Safety Vision/Mission and Principles

▪ Develop safety policies and program

▪ Identify workplace hazards

▪ Encourage safety conversations

▪ Monitor safety program

▪ Reduce frequency of injuries

▪ Reward safe behavior

Safety Committee

Thank you. Develop Your Safety Culture

Primary structure for defining and supporting Culture Safety:• Prevention – includes policies, goals, controlling hazards.

• Capability – includes passive, proactive & integrated employee engagement

• Compliance – includes best practices, audits, scorecards

Safety Program Structure for Success

Thank you. Prevention Component

Prevention is the stabilizing structure of a Safety Plan. It prepares the environment by:

• Providing policies and procedures to follow.

• Establishing goals to benchmark against.

• Implementing hazard controlthrough guarding, technology and assessments.

Prevention Component

• Establish health & safety policies.

• Develop specific rules based on the policy.

• Provide a procedure to accomplish the rule requirements.

Policies & Procedures

Safety Rules• All injuries must be reported as

soon as possible.• PPE must be worn at all times

while on the plant floor.• All guards must be kept in

place.• All OSHA Safety Standards

concerning LOTO of energized equipment will be followed.

Benchmark Safety Goal

Establish smart goals to benchmark your status and target success. Each goal may requires a different approach.

• 40% - Basic Safety 101 Training

• 20% - Procedure Changes

• 10% - Habits & Technology

10 -70% Fewer Incidents by 2017

ASSE Symposium “Achieving World-Class Safety”

OSHA Top 10 Violations 2017

(October 1, 2017)

Standard Total Violations

1 Fall Protection (1926.501) 6,072

2 Hazard Communication (1926.1200) 4,176

3 Scaffolding (1910.451) 3,288

4 Respiratory Protection (1910.134) 3,097

5 Lockout/Tagout (1910.147) 2,877

6 Ladders (1926.1053) 2,241

7 Powered Industrial Trucks (1910.212) 2,162

8 Machine Guarding (1910.212) 1,933

9 Fall Protection Training (1926.503) 1,523

10 Electrical-Wiring Methods (1910.305) 1,405

Implementing Hazard Control

Engineering Controls(Safeguarding Technology)

Warnings(Automatic or Manual)

Protective Measures

Eliminate the Risk • Design It Out• Remove the hazard during redesign

Substitution

Examples

• Fencing, Barriers, Fixed Covers• Process Substitution

• Interlocks, Light Curtains, Safety Mats• Monitoring Relays, Safety PLCs

• Signs, Warnings, Annunciation Lights• Audible, Visible, Systems, Barriers

• Training, Communications, Processes• Work practices, Work Management

Most Effective

Least Effective PPE

(Personal Protection Equipment)

Administrative Controls(Planning & Processes)

• Available, Effective• Easy to Use

NFPA 70E 2018

Thank you. Capability Component

Capability is the skill component of a Safety Plan. It prepares employees by:

• Adding passive engagement awareness to the environment.

• Establishing proactive engagement through orientation, formal training and coaching.

• Encouraging integrated engagement that is skill driven and incorporates employee action.

Capability

Reflective:

• Requiring no employee action.

• Building basic awareness.

Examples:• Safety awareness posters• Equipment labels• Hardhat stickers• Visitor welcome videos

Passive Engagement

Planned:

• Encourages employee actions.

• Improves essential awareness.

Examples:

• New employee orientation

• Required training▪ PPE, GMP, LOTO, Area and Equipment

• Hands-on Mentoring▪ Shift meetings

▪ Safety checklist, peer-accountability

Proactive Engagement

Formal Training

Formal training transfers andvalidates knowledge of policies, rules, procedures.

• Include safety in agenda

• Provide class discussion

• Include hands-on validation of ability

Hands-on:

• Requires employee action.

• Improves awareness.

Example:

• Safety Observation Cards

• Job Hazard Checklist

Integrated Engagement

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Job Hazard Checklist

Top 10 Causes of Most Disabling Injuries

Job Hazard Checklist

38

• Safety Communication / Documentation / Training

• General Area Safety and PPE

• Chemical and Fire Hazards

• Hand and Portable Power Tools

• Material Handling

• Electrical Safety

• Construction-Related Hazards

• Promote safety through awareness

• Provide areas to improve training and communication

• Provide process for regular inspection of equipment and work areas

• Opportunity to decrease injuries and near misses

Job Hazard Checklist Best Practices

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Facility Job Hazard “Heat Map”

ChecklistItem

Pre-Filling Filling Capping Casepacking Wrapping Warehouse

1 Y DK DK Y DK DK

2 Y DK Y Y N Y

3 Y Y Y Y Y N

4 Y N Y N N N

5 DK N Y Y DK DK

6 Y Y Y Y N Y

7 Y Y Y DK Y N

8 Y Y Y DK Y DK

9 Y Y Y Y Y Y

10 Y DK Y Y Y Y

11 Y N Y Y Y Y

Capability is the skill component of a Safety Plan. It prepares employees by:

• Adding passive engagement awareness to the environment.

• Establishing proactive engagement through orientation, formal training and coaching.

• Encouraging integrated engagement that is skill driven and incorporates employee action.

Capability

Thank you. Compliance Component

Compliance is the discipline element of a Safety Plan. It measures success by:

• Establishing best practices tofollow.

• Implementing hazard preventionthrough audits.

• Providing opportunities for success

through scorecards.

Compliance

A best practice is a method or technique that consistently shows superior results and is used as a benchmark.

• Procedures▪ Continuous procedure validation & update

▪ PPE stations replenished every shift

• Coaching▪ Formal methodology in place

▪ Peer accountability

• Discipline & Awards▪ Violation policy

▪ Consistent observations

Best Practices

• Reward for Performance▪ Recognition related to "lagging indicators”

▪ If below, award provided – if above, no award provided

▪ Employees meet points, by criteria, receive a gift or cash

▪ Can result in encouragement to “fail to report” incidents

• Reward for Observation & Prevention▪ Recognition related to “leading indicators” of awareness and

prevention

▪ 12 Safety Hazards & Ideas Cards completed per month

▪ Employee and/or team receive points for safe solution idea

▪ Can result in peer accountability and open discussion

Safety Award Program examples

53 Weeks of Safety Overview

Content Handout

• Overview

• Details

• Case Study

• Activity

• OSHA Reference

Primary structure for defining and supporting Culture Safety:• Prevention – includes policies, goals, controlling hazards.

• Capability – includes passive, proactive & integrated employee engagement

• Compliance – includes best practices, audits, scorecards

Safety Program Elements for Success

From OSHA Safety Program to World Class Safety Culture

Management Commitment and Employee Involvement

Worksite Analysis

Hazard Prevention and Control

Safety and Health

Training

• Vision / Mission

• Principles

• Safety Committee

• Compliance

▪ Rules

▪ Regulations

▪ Audits

▪ Scorecards

• Prevention

▪ Policies

▪ Goals

▪ Hazard

Control

• Capability

▪ Passive

Engagement

▪ Pro-Active

Engagement

▪ Integrated

Engagement

World Class Safety Culture Components

• Inadequate machine guarding/anchoring

• No fall protection for employees climbing >12ft high

• Lack of training• No records of equipment

inspections• Unlabeled containers• Outdated Safety Data Sheets

(SDS)• Lack of appropriate PPE

If You Could Be Like Mike.....

• A strong safety culture begins when we start to make safety a habit, a core value that is practiced constantly .

• Spend less time & money on initiating safety programs, and more on follow-up and reinforcement activities.

• Identify your own at risk behaviors.• Improve safety culture by removing hazards - anything

that has the potential to contribute to an incident.• For a strong safety culture, create a level of trust that

allows people to speak up freely about at- risk behavior, regardless of seniority.

• Risk assessing in a strong safety culture is consciously and purposely deciding how not to get hurt.

• When giving feedback, focus on the act, not the attitude.

Keys to Building Your Safety Culture

Thank You!

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855.794.7659

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Questions

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