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Creating a Accident Free Work Environment Why Not Set Your Goal to ZERO! Presented By: Betty Knox Agenda The Swiss Colony Defining Zero Accidents Measuring Safety Performance Creating a Zero Accident Program Facilities 13 Cities Madison Dickeyville Peosta DeWitt Monroe Janesville Oak Brook Davenport Savanna Clinton Hannibal Reno, Nevada Shanghai, China 12 Jets 22 Pilots Is Zero Accident Possible? 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? Zero Accidents 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 Why Not Aim For Zero! Defining Zero Accidents 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! Measuring Safety Performance Employee Perception of Safety Where is your Company now in safety performance? Measuring the Safety Management System Problems with Statistics 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. Measuring Performance 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 Safety Performance 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 Performance Hours 5000000 Rate 20 Initial Hazard ID/RTW Efforts 4500000 18 4000000 16 3500000 14 3000000 12 First Aid Contact Log Introduced 2500000 2000000 10 Safety Accountability Implemented Incentives OSHA Compliance Capital Expenditures 8 Comprehensive Safety Audit 1500000 Safety Awareness LOTO /Equipment 1000000 Train the Trainers Hazard Assessments 6 4 Accountability Training 500000 De-Centralized Safety Function 2 Revised Fork lift Target Zero 0 0 2009 2008 2007 2006 2005 2004 2003 2002 2001 2000 1999 1998 1997 1996 1995 1994 1993 1992 1991 1990 Measuring - Audit Results 2004 Score % 2005 Score % 04-05 % Variance 2006 Score % 05-06 % Variance 2007 Score % 06-07 % Variance 2008 Score % 07-08 % Variance 2009 Score % 08-09 % Variance Facility 1 71% 100% 29% 97% -3% 99% 2% 100% 1% 99% -1% Facility 2 78% 98% 20% 97% -1% 98% 1% 99% 1% 98% -1% Facility 3 63% 100% 37% 97% -3% 99% 2% 98% -1% 98% 0% Facility 4 - - - 99% - 98% -1% 98% 0% 98% 0% Facility 5 - 85% - 96% 11% 76% -20% 98% 22% 98% 0% Facility 6 - - - - - - - 94% 0% 98% 0% Facility 7 78% 99% 21% 96% -3% 95% -1% 96% 1% 98% 2% Facility 8 68% 97% 29% 97% 0% 95% -2% 97% 2% 98% 1% Facility 9 67% 88% 21% 96% 8% 92% -4% 97% 5% 97% 0% Facility 10 50% 93% 43% 90% -3% 95% 5% 93% -2% 97% 4% Facility 11 66% 98% 32% 98% 0% 96% -2% 96% 0% 93% -3% Facility 12 77% 99% 22% - - - - - - - - Facility 13 66% 99% 33% - - - - - - - - Total 71% 96% 26.9% 97% 0.6% 94% -2.88% 97% 2.9% 98% 0.2% Department Measuring Against Industry Food Manufacturing 40 Production 35 30 27.32 24.59 25 20 20 19.5 20.56 18.8 17.6 17.1 18.42 15 15 10 5 17.08 16.3 16.97 10.71 14.17 14.5 13.65 14.86 16.5 14.95 12.76 10.73 13.6 12.43 11.9 8.4 7.7 10.3 7.4 6.4 5.8 5.8 5.03 5.88 3.71 3.47 4.96 2.32 0.00 0 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Data Collected from Bureau of Labor Statistics NAICS Code 3119 Safety Management System (SMS) 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 Our Safety Management System key elements: - 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 Safety Management System Flow Chart Safety System Flow Chart Information link Control Link Policy Organizing Auditing Policy Development Organizational Development Planning and Implementing Measuring Performance Reviewing Performance Developing Techniques Planning, Measuring, Reviewing, Monitoring Feedback Loop to Improve Performance Measuring Safety Performance 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 Prior to Implementation we Asked 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? Are we succeeding in eliminating or reducing hazards? Are we ready for Zero Accident Program? YES! Creating Zero Accident Program Some of the Challenges Changing the Perception of Safety Making a impact on our Seasonal Temporary Workforce (~5500) Impacting our Diverse Workgroup Additional Resources in Safety Preparing for Zero Accident Plan 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 Employee Perception Survey QUESTIONS ABOUT SAFETY 2005 2006 2007 2008 2009 Variance 08-09 Average Variance Dept/CA Quest# 49 I receive the appropriate level of safety training to perform my job safely. 2.16 1.92 2.23 2.33 1.99 -0.34 1.57 0.42 49 50 The company does not compromise safety for productivity. 2.41 2.18 2.25 2.23 2.37 0.14 1.75 0.62 50 51 I understand my role and responsibilities in keeping my work area clean from debris and clutter. 2.27 2.19 2.23 2.17 1.73 -0.43 1.37 0.36 51 52 I know what to do in case of an emergency (fire, tornado, etc.). ---- ---- ---- ---- 1.62 ---- 1.52 0.10 52 53 I have been made aware of the new safety initiative "Target Zero - Zero Accident Program." ---- ---- ---- ---- 1.72 ---- 1.68 0.04 53 54 My supervisors are able to answer safety related questions. ---- ---- ---- ---- 1.64 ---- 1.56 0.08 54 55 Safety incentive programs motivate met ot do my job in a safe manner. 2.28 2.07 2.26 2.30 2.10 -0.20 1.79 0.31 55 56 I actively participate in the company's safety programs. 2.58 2.39 2.45 2.54 2.38 -0.17 1.97 0.40 56 57 The company provides a safe working environment. ---- ---- ---- ---- 1.87 ---- 1.52 0.35 57 2.34 2.15 2.29 2.31 1.94 -0.38 1.64 0.30 SECTION SCORE Auditing the Elements Company Average Record Verification Score Physical Audit Score Employee Knowledge Score Section 1: Blood Borne Pathogens 6 / 6 Section 1: Blood Borne Pathogens 10 / 10 Section 1: Blood Borne Pathogens 43 / 44 Section 2: Hazard Communication 5 / 6 Section 2: Hazard Communication 4 / 4 Section 2: Hazard Communication 29 / 31 Section 3: Lockout Tagout 5 / 6 Section 3: Lockout Tagout 2 / 2 Section 3: Lockout Tagout 37 / 37 Section 4: PPE 7 / 7 Section 4: PPE 2 / 2 Section 4: PPE 24 / 24 Section 5: OSHA Refresher 10 / 10 Section 5: Equipment Operation 2 / 3 Section 6: Fire Severe Weather Drill 20 / 21 Section 6: Equipment Operation 3 / 4 Section 6: Fire Severe Weather Drill 5 / 5 Section 6: Equipment Operation 9 / 9 Section 7: Fire/Severe Weather Drill 5 / 6 Section 7: Fork Lift Program 11 / 11 Section 7: Fork Lift Program 9 / 9 Section 8: Fork Lift Program 5 / 5 *Section 8: Electrical 4 / 4 Section 8: Ergonomics 10 / 10 Section 9: Ergonomics 2 / 2 Section 9: General Housekeeping 3 / 4 Section 10: Personnel Cage 13 / 14 Section 10: Monthly Safety Audits 4 / 4 Section 10: Personnel Cage 1 / 1 Section 11: First /Aid /CPR 10 / 10 Section 11: Personnel Cage 2 / 2 Section 11: First /Aid /CPR 3 / 3 Section 12: OSHA Inspection 4 / 4 Section 12: First /Aid /CPR 3 / 3 Section 12: OSHA Inspection 4 / 4 Section 13: Fall Protection 7 / 7 Section 13: OSHA Inspection 1 / 1 Section 13: Fall Protection 4 / 4 Section 16: Ammonia 4 Section 14: Fall Protection 2 / 2 Section 15: Hearing Conservation 3 / 3 Section 16: Ammonia 3 / 3 Section 17: Safety Shower/ Eye Bath 1 / 1 Section 18: Documentation 0 / 1 Section 19: Accident Investigation 5 / 5 Section 20: Safety Action Plans 12 Average Sub-Total 71 219 4 / 224 98% 12 / Average Sub-Total 55 Total Average Score: 135 / 139 97% / 57 Average Sub-Total 9 / 10 Setting Goals 2010 Target Zero - Zero Accident Program Location/Department 2009 Total Hours 12/31/2009 2009 Total Claims Target Zero Goal (1) Stretch Goal (2) Reach Goal 2009 Final IRR Accident Incidence Accident Incidence Accident Incidence Frequency Rate Frequency Rate Frequency Rate 2010 Projected Hours Facility A Department One Two Three 622,268 145,580 155,528 1 0 3 0.32 0.00 3.86 0 0 0 0.00 0.00 0.00 1 0 1 0.34 0.00 1.32 2 1 2 0.67 1.37 2.63 597,000 146,000 152,000 Department One Two 17,803 127,749 1 8 11.23 12.52 0 0 0.00 0.00 0 2 0.00 2.97 1 3 14.79 4.45 13,520 134,846 Department One Two Three four Five Six Seven 342,947 27,901 203,377 260,150 31,629 1,207,636 60,533 5 0 0 1 0 3 0 2.92 0.00 0.00 0.77 0.00 0.50 0.00 0 0 0 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 3 0 0 1 0 2 0 1.99 0.00 0.00 0.95 0.00 0.35 0.00 6 1 1 2 1 3 1 3.98 8.50 1.07 1.90 5.87 0.52 3.31 301,174 23,540 187,152 210,952 34,100 1,148,900 60,481 Department One 68,423 0 0.00 0 0.00 0 0.00 1 2.80 71,366 Department One 93,205 1 2.15 0 0.00 1 2.07 2 4.14 96,608 Department One 441,493 0 0.00 0 0.00 0 0.00 1 0.53 375,000 Department One 196,610 0 0.00 0 0.00 0 0.00 1 1.03 195,000 Department One 57,020 4,059,852 0 25 0.00 1.23 0 0 0.00 0.00 0 11 0.00 0.58 1 30 3.09 1.57 64,660 3,812,299 Facility B Facility C Facility D Facility E Facility F Facility G Facility H TOTALS Preparing for Zero Accident Plan 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 Accountability / Incident Rate Review ACCOUNTABILITY S CORE INCIDENT RATE 2010 DEPARTMENT 2005 2006 2007 2008 2009 2003 Facility A 2.45 2.75 2.95 1.18 1.38 Facility B 4.35 2.35 3.40 1.48 1.20 Facility C 1.60 2.05 1.45 1.50 1.50 5.19 Facility D 1.00 1.00 2.20 1.38 2.90 12.80 Facility E 2.75 1.45 0.95 0.95 2.40 Facility F 1.25 3.00 1.80 1.28 1.28 10.32 Facility G 1.00 1.25 2.45 1.50 1.00 Facility H 1.40 2.25 1.45 1.45 1.05 Facility I 2.25 1.35 1.40 1.33 Facility J 2.25 1.25 1.45 Facility K 1.85 2.40 2.55 S tretch Goal Reach Goal 9.54 6.06 2.92 0.00 1.99 3.98 6.07 2.15 0.00 2.07 4.14 4.67 3.60 4.70 4.11 2.56 0.64 0.00 0.95 1.90 11.62 5.21 1.18 7.65 4.04 12.52 0.00 2.97 4.45 14.39 6.54 3.23 1.10 3.86 0.00 1.32 2.63 9.18 6.36 9.39 3.99 4.68 0.00 0.00 0.00 3.09 0.00 1.58 3.46 1.73 8.01 2.16 0.00 0.00 0.00 2.80 6.63 10.78 3.80 5.25 2.21 2.49 0.00 0.00 0.00 3.31 1.28 1.48 2.55 2.10 0.80 1.09 0.41 0.20 0.00 0.00 0.89 1.50 1.50 0.00 4.84 8.99 0.00 0.00 0.00 0.00 0.00 0.00 5.87 2.48 1.23 0.00 6.26 4.43 4.48 9.35 5.60 0.00 0.00 0.00 8.50 0.50 0.00 ------- ------ Facility N ------- ------- ------ ------ ------ 9.10 Facility O ------- ------- ------ ------ ------ 8.63 ------- 1.46 1.52 ------- ------- ------ 2.00 2009 12.71 ------- 1.92 2008 8.66 ------- 2.01 2007 14.94 ------- Facility M TOTALS 2006 2.79 ------- 2.98 2005 18.37 1.23 6.86 2004 2010 Goal 4.95 ------- ------- ------- ------- ------- 4.40 ------- ------- ----- ----- ----- ----- ------- ------- ------- ------ ------ ------ ------ ------- ------- 3.45 ------3.34 3.46 3.23 1.85 1.18 0.00 0.35 0.58 0.52 1.57 Safety Accountability Managerial Employee Safety Accountability Review Form Employee Name: Employee Number: EXAMPLE Department: 545 Review Period: 01/01/2009 to 12/31/2009 Performance Rating Scale Cost Containment Rating Scale 1 = Consistently Exceeds Job Requirements 2 = Commendable 3 = Fully Competent 4 = Needs Development 5 = Unsatisfactory Work Performance 100% 90% 80% 60% 40% 1 = 10%+ Savings beyond Target Amount 2 = 5-9% Savings beyond Target Amount 3 = +/- 4% Difference from Target Amount 4 = 5-9% Loss beyond Target Amount 5 = 10%+ Loss beyond Target Amount Evaluation Category 1. (20%) Incident Rate - Maintained Filed Claim Incident Rate w ithin departmental goals: At or below goal = 1 point 1-5% over = 2 points Actual Rate = 5-10% over = 3 points 10-20% over = 4 points Goal Rate = 21%+ = 5 points % Rating = 2. (15%) Proactive Safety Management - Takes initiatives to identify safety concerns and Final Score % Rating of the established Safety Action Plan as determined by the departmental safety team to ensure safety initiatives are being completed on an annual basis. Final 0-1 missed items = 1 point 2-3 misses = 2 points Score 4 misses = 3 points 5 misses = 4 points 6+ misses - 5 points 5. (15%) Safety Training and Policy Enforcement - Enforces safety procedures as outlined in Weighted Score 0.20 0.2 1.00 0.15 0.15 1.00 0.15 0.15 1.00 0.15 0.15 1.00 0.15 0.15 1.00 0.10 0.1 1.00 0.10 0.1 142 145 98% 12 12 safety training courses and company/departmental policies, carrying out the responsibilities as outlined in the responsibility charts. 6. (10%) Cost Containment - (Average is set by removing highest and low est total cost over Cost Analysis: Weight 1.00 0 2.6 0.00 accident potentials by enforcing safety audits and fixing problems, prompting good housekeeping efforts, soliciting safety suggestions from employees, and actively developing controls to assure the safety concerns and potentials are minimized or eliminated. 3. (15%) Facility Compliance Audits - Annual Facility Audit score for OSHA Regulations: 95-100% = 1 point 89-94% = 2 points 78-82% = 4 points 83-88% = 3 points 77% and Below = 5 points 4. (15%) Department Safety Action Plan Implementation - Enforces implementation Rating 1.0-5.0 past 7 year period - not including current year.) Actual 5 Year Average $17,284.00 $5,652.00 Total WC Loss Target Level - (Average cost/claim past 7 year period * Frequency goal) % of Dept. Loss w ith Domain of Control Cost Containment Rating: % Difference betw een actual WC loss and the Target Level: (Circle One) Over 7. (10%) Accident Management - Enforces post-accident employee follow -up and case management procedures to ensure proper accident management as outlined by company policy; including identifying and implementing preventative measures. $0.00 0.0% Under 100.00% Total Score: 1 Comments Supporting the Above Rating: SAFETY BONUS SUMMARY Safety Bonus Dollars Available Stretch Goal Dollars Available $4,000.00 $800.00 Safety Bonus Dollars Earned Stretch Bonus Dollars Earned TOTAL: APPROVALS SUPERVISOR/MANAGER EMPLOYEE $800.00 $160.00 $960.00 Preparing for Zero Accident Plan 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 Key Components Employee Involvement Accident Analysis Management Commitment Elements To Achieving Zero Accidents Hazard Identification Accountability Awareness Training 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. Identified the Elements 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. Introduction of Target Zero 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 Target Zero Implementation Plan 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 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 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 Phase 3: Communication and Awareness Safety Training - Safety Bulletin Board Employee Annual Safety Meeting Weekly Safety Communication Talk Monthly Safety Review Update on Safety Day 12 Monthly Required Safety Talk 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 Phase 4: 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 Promoting Target Zero Safety Day Awareness Incentive Target Zero Group Incentive Corporate Safety Incentive 1 Month 3 Month I-month 2-months 3-months 4-months 5-months 6-months 7-months 8-months 9-months 10-months 11-months I Year Grand Prize 1 Year 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. 6 Months 9 Months 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. 5 5 10 5 5 20 5 5 25 5 5 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 . Benefits of a Zero Accident Plan Assigns Authority and Accountability Ensures Compliance with all safety rules Establishes two-way Communication Provides for Periodic safety inspections Requires Investigation of Accidents & Injuries Corrects hazards when observed or discovered Specifies general & job-specific safety training Maintains Inspection & Training Records Demonstrates Commitment “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!