SEPTEMBER 25, 2017

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Approaches for Staying at Forefront of Worker Safety

Paul Schaum, COOPretzels, Inc Chair; OpX Worker Safety Solutions Group

1. Introduction to PMMI’s OpX Leadership Network2. Worker Safety Solutions Group

– Description of Opportunity– Objectives – Tools in Development– Q & A

AGENDA

community of Manufacturing, Engineering & Operations professionals

Over 250 companies on solving common operational challenges

Develop best practices and protocols forindustry

MOVING OPERATIONAL EXCELLENCE FORWARD

PMMI FOUNDED OpX LEADERSHIP NETWORK in 2011

BEST PRACTICES FOR INDUSTRY, BY INDUSTRY

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Plan for Fall -Winter 2017

Peer Review & Pilots

Release Publication

Innovation Stage at PELV

Webinar -Pro Food World

CIP September October Wednesday 9.27

Worker Safety October November Monday 9.25

Secured Vendor January February October 26

RFP November December Tuesday 9.26

NEW PUBLICATIONS IN PIPELINE

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Cultivating a Culture of Safety in Food and Beverage PlantsBy Kevin T. Higgins, Managing EditorOct 06, 2014

The good news in workplace injuries and fatalities in general and in food and beverage manufacturing in particular is that rates are continuing a slow, steady decline.

The bad news is that 46 food workers died last year, according to the Bureau of Labor Statistics, and another 76,900 food, beverage and tobacco workers were injured

seriously enough to require time away from work.

THE NEED TO DRIVE TO ZERO

2013 TRIR World Class

All Manufacturing (21 categories)

TRIR .6 1.3 - 6.4

Food & Beverage 5.0 - 5.5 (#2)

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24% of food workers have been injured at their current job, and 17% of workers were injured in their first year.

42% of workers rarely or never receive coaching from their manager or supervisor, and 20% said they received too little training before starting their job.

37% of workers and 43% of supervisors agree that training is sometimes too complicated or difficult to understand.

Food manufacturing workers have a 60% higher rate of occupational injury and illness than workers in other industries. The risk of occupational death is 9.5 times higher for food industry workers than in non-food jobs.

Source: Antea Group study 2016

THE NEED TO DRIVE TO ZERO – More data

370,000,000 on worker safety

Thousands of pages

24% 42% 37% 60%

STRATEGIC OBJECTIVE: DRIVE TO ZERO

To assist CPGs and their OEMs and other suppliers in implementing best practices to mitigate conditional (equipment, line configuration, materials and environment) and behavioral (thinking, acting, choosing and deciding) risks related to worker safety.

Worker Safety Solutions GroupAbbottAmwayBaxterBumble Bee FoodsH-E-BJM SmuckerLand O' FrostLand O' LakesMettler ToledoMGS MachineNatures BountyNestlePressed JuiceryPretzels, IncRA JonesSMCSugar - CreekWhitewaveWornick Foods

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TOOLS IN DEVELOPMENT – WORKER SAFETY READINESS SURVEY

Key Perspectives – from the workforce

Commitment to a Culture of Safety Leadership & Equipment

Commitment to a Safety Plan Leadership & Equipment

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Leadership(Behavioral)

Leaders at all levels in our company are committed to developing and sustaining a culture of safety throughout the company.

Leadership in our company ensures that the right amounts of resources – especially human and financial resources – are put in place to support a successful culture of safety

CULTURE OF SAFETY- SURVEY AND GUIDANCE

Guidance

Best systems have buy-in from the top; • desire for leadership at all

levels to be more proactive• need to set the tone of the

culture - say/do disconnect needs to change

• safety top priority at all times, not after an incident

Open and transparent communication allows associates the information needed to make effective decisions with regards to value added application of timeand funding.

(see OpX Workforce Engagement)

Equipment Safety(Conditional)

Our company is keenly aware of and addresses the leading worker safety risks, especially as they relate to equipment.

Our company has a steadfast adherence to industry equipment standards relative to our manufacturing processes, e.g. ANSI/PMMI B155.1

Guidance

Company awareness and adherence to standards for worker safety

PMMI risk assessment for equipment and the end user. • Safe design, safeguarding

and safe use of equipment viewed as a lifetime risk assessment,

• Roles and responsibilities in integration of different pieces of equipment,

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COMMITMENT TO A SAFETY PLAN - SURVEY AND GUIDANCE

Leadership(Behavioral)

Leadership has seen to it that we have a comprehensive safety plan in place in our company.

There is a tight link between the metrics in our safety plan and the awareness program for everyone in our organization.

Guidance

Best in class; Autonomous Safety...• There is a dedicated safety

professional at the site• They are the subject matter

expert that enables safety to flourish

• Front line associates own the safety at line: e.g. fork lift drivers as SMEs for fork lift safety, a line operator as the SME for the line

Create greater awareness and incentives for safety;• Focus on leading indicators, but

not on lagging indicators• Supervisors/managers bonus

program related to reduction in incidences,

Equipment Safety(Conditional)

Expectations regarding worker safety are clearly communicated and well understood by all workers.

Anyone in the company has the authority to stop production if a serious safety condition is found to exist.

Conditional

Clarity and Understanding of expectations by each worker

Leadership must use the principles and values of the organization to provide the associates and teams with guidance for decision making. Leadership shoulduse the concept of “smart trust”. (see OpX Workforce Engagement)

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DRILL DOWN AREAS - SURVEY AND GUIDANCE

ElectricalElectrical Safety is an integral part of our Safety Program

We have a well-developed Arc Flash Training and awareness program for our employees;

•Training is monitored and tracked•Awareness of Arc flashes incidents

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AmmoniaThere is a dedicated person responsible for managing the PSM program

There is a robust PM maintenance program in place for the ammonia system

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Machine Safeguarding

Our company has a written Machine Safeguarding Program that is maintained at the facility and is available to employees to review.

Our company requires start-up procedures to include Machine Safeguarding inspections.

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SEPTEMBER 25, 2017

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Approaches for Staying at Forefront of Worker Safety

Q&A

Paul Schaum, COO, Pretzels, Inc

More Info: Opxleadershipnetwork.org