Management Commitment and Employee...
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I n j u r y F r e e Brad Riker Safety Coordinator National Office Furniture Jasper 11 th Avenue Vince Cooke Director, Employee Safety and Security National Office Furniture Management Commitment and Employee Engagement I n j u r y F r e e Agenda • Management Commitment • Employee Engagement • Daily Start Up meetings • Question and Answers
Transcript of Management Commitment and Employee...
Injury
Free
Brad RikerSafety Coordinator
National Office Furniture Jasper 11th Avenue
Vince CookeDirector, Employee Safety and Security
National Office Furniture
Management Commitment and Employee Engagement
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Agenda
• Management Commitment
• Employee Engagement
• Daily Start Up meetings
• Question and Answers
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We strive for an “INJURY FREE” working environment for our people.
‘’s Vision in Safety
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A Brief Overview of Kimball International
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•Our motto is “We Build Success”•Established in 1950
•We go to market in 3 brands of Furniture segments •National Office Furniture•Kimball Office Furniture
•Kimball Hospitality
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National Office Furniture Jasper 11th Avenue
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Our History with the VPP Program
8 VPP Sites certified since 2000 (8 Star)
• Springs Valley Manufacturing – 2000*• Kimball Office Jasper - 15th Street – 2000• Kimball Electronics Jasper - 2004• Logistics – 2008• National Office Furniture - Santa Claus – 2009• Kimball Office Jasper - Cherry Street - 2009• National Office Furniture - 11th Avenue – 2010• Kimball Office Salem - 2012
We have 7 SGE (Special Government Employee) employees
*no longer a current site
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Partnership
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Benefits of VPP
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9.9 10
9.1
7.6 7.5
5.7
4.4
3.5
2.8
1.71.1 1 1 0.9 0.9
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1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
KIMBALL INTERNATIONAL All Injury Rate
91% reduction
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1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
NATIONAL INJURY RATE
86% reduction
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11.5
10.29.5
7.4
8.3
6.86.3
5.56
2.8
0.81.5
1.20.7
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1.4
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1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
NOF – 11th Avenue All Injury Rate
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41
5
91% reduction
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Safety Management System
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Management Commitment
Employee Involvement
Worksite Analysis
Hazard Prevention &
ControlTraining
Top Management Organized Safety Team Job Hazard Analysis Lead Measures New Employee Orientation
Safety is a Value Safety Suggestion System Trend Analysis Planning Matrix Documentation on Training
Safety Manager Local Emergency Response Team Audit Process Behavioral Based Safety Weekly Topics
Adequate Resources First Aid Team Injury /Incident Evaluation Emergency Planning Drills Contractors Safety
Line Accountability for Results Ergonomics Team Job Safety Procedures Ergonomics Ergonomics
Mission Statement with Policy/Commitment
Safety Representatives Program
Industrial Hygiene Monitoring Near Miss Program Employees assist in training
Goal Setting BBS Site Champions External Resources Written Safety Plans Specialized Training for Supervision
All Relative Items Receive Closure A.E.D. Program Personal Protective
Equipment program
Safety Performance Feedback
Housekeeping Rating System Early Intervention Program
Return to Work Program Maintenance Support
Contractors Safety ProgramOrganized filing system
SAFETY MANAGEMENT SYSTEM
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Management Commitment
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Lead Measures
Determine the success of your Lag Measures
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Lead Measures
99 99 99 99 99 99 99 99 99
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May June July Aug Sept Oct Nov Dec Jan
% of employees BBS Site ChampsGoal = 100%
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Lead Measures
100 100 100 100 100 100 100 100 100 100 100 100 100
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Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan
% of internal Quarterly Safety Assessments Goal = 100%
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Lead Measures
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Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan
# of Job Hazard Analysis completed
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Lead Measures
4042
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(5)
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Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan
# Near Misses or Safety Improvement per month
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Lead Measures
2 2
1
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5
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10
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Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan
# Ergonomic Improvements per month
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Monthly Management Review Meeting
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Safety Review Board February 11,2015 January Results
•Opening Comments- Director Operations•Review Safety Performance Tracking Sheet – Safety •NOF Safety Results YTD – Safety•Update on Near Miss Program / Safety Improvement –Safety•Participation by area in Near Miss Program- Safety•BBS activities •Safety Awareness Activities – Team•Review 6S open/corrective actions & audit scores •Open Discussion
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NOF 11th Avenue
2014 Calendar Year Safety Tracking
Goal Met
Goal not Met total hrs
2013 Hrs 32,247 42,338 56,976 45,010 65,027 49,023 47,420 64,923 45,454 49,923 65,882 47,262 611,485
2014 Hrs 45,394 40,624 43,911 42,432 50690 58639 57128 55934 56115 58743 48,639 56,743 614992
#Improvement Priority Measure 2014 Goals 2014 Jan Feb Mar April May June July Aug Sept Oct Nov Dec
2014 Actual YTD
1 0 Lost Time Incidents # of LT 0 2013 0 0 0 0 0 0 0 1 1 0 0 0 2
2014 0 0 0 0 0 0 0 0 0 0 0 0 0
2 Reduce All Injuries by 50% # of Injuries 32013 0 1 0 0 1 1 1 0 1 1 1 0 7
2014 1 0 0 0 1 0 0 1 0 1 0 1 5
3 Reduce All Injury Rate by 50% All injury rate 12013 0 4.75 0 0 3.08 4.08 4.22 0 4.4 4 3 0 2.29
2014 4.4 0 0 0 3.9 0 0 3.7 0 3.4 0 3.5 1.6
4 Ergonomic Improvements 2 per Month
2
Plan 2 2 2 2 2 2 2 2 2 2 2 2 24
2014 4 2 1 8 4 6 2 3 5 4 5 10 54
5 Employee suggestions from the safety tour list / action list # of Suggestions
2013 11 13 12 12 10 10 15 12 11-10 12-30 10-26 4-23 221
2014 44 31 42 23 19 26 35 22 25 14 17 26 324
6 Employee suggestions corrective action rate from safety tour list / action list. %
90% 2014 96% 63% 57% 100% 100% 85% 100% 77% 100% 100% 100% 89%100%
7 Safety Improvements / Near Misses Reported
# reported per month
2013 33 43 37 39 28 24 31 36 42 43 43 29 428
2014 40 42 39 34 43 40 34 41 50 72 53 60 548
8 Number of BBS Site Champions % of Employees
Year End 100%
2013 7 7 7 7 7 7 7 7 7 7 7 7 7%
2014 33% 60% 92% 99% 99% 99% 99% 99% 99% 99% 99% 99% 99%
9 JHA Completions = Area Triangles / Safety Team 18 per month
18
Plan 10 18 18 18 18 18 18 18 18 18 18 18 208
Actual 16 20 14 20 19 14 20 18 18 18 18 16 211
10 JHA Corrective Action # open # closed Actions
Open 49 42 22 38 35 27 40 31 31 24 17 12 368
Closed 35 29 13 27 28 19 31 17 21 14 4 4 242
11 Conduct Safety Review Board Meeting 1 per month
12
Plan 1 1 1 1 1 1 1 1 1 1 1 1 12
Actual 1 1 1 1 1 1 1 1 1 1 1 1 12
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NOF 11th Avenue 2015 Calendar Year Safety Tracking
Goal Met
Goal not Met total hrs
2014 Hrs 45,394 40,624 43,911 42,432 50,690 58,639 57,128 55,934 56,115 58,743 48,639 56,743 614,9922015 Hrs 48,640 48,640
#Improvement Priority Measure
2015 Goals 2015 Jan Feb Mar April May June July Aug Sept Oct Nov Dec
2014 Actual YTD
1 0 Lost Time Incidents # of LT 0 2014 0 0 0 0 0 0 0 0 0 0 0 0 02015 0 0
2 Reduce All Injuries by 50% # of Injuries 32014 1 0 0 0 1 0 0 1 0 1 0 1 5
2015 0 0
3 Reduce All Injury Rate by 50% All injury rate 1
2014 4.4 0 0 0 3.9 0 0 3.7 0 3.4 0 3.5 1.6
2015 0
4 Ergonomic Improvements 2 per Month2
Plan 2 2 2 2 2 2 2 2 2 2 2 2 24
2015 8
5Employee suggestions from the safety tour list / action list
# of Suggestions
2014 44 31 42 23 19 26 35 22 25 14 17 26 324
2015 20
6Employee suggestions corrective action rate from safety tour list / action list.
%
90% 2015 100%
7 Safety Improvements / Near Misses Reported
# reported per month
2014 40 42 39 34 43 40 34 41 50 72 53 60 548
2015 55
8 Number of BBS Site Champions
% of Employees Year End
100%
2014 33% 60% 92% 99% 99% 99% 99% 99% 99% 99% 99% 99% 99%
2015 99%
9 JHA Completions = Area Triangles / Safety Team 18 per month
18
Plan 18 18 18 18 18 18 18 18 18 18 18 18 211
Actual 18
10 JHA Corrective Action # open # closed Actions
Open 10Closed 10
11 Conduct Safety Review Board Meeting 1 per month
12
Plan 1 1 1 1 1 1 1 1 1 1 1 1 12
Actual 1
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Total Near Misses forJanuary, 2015 = 55
By Area:N/W & Cutting = 16
Area 1,4 & M/R = 14
Area 2 = 3
Area 3 = 12
Material Handling = 5
Maintenance = 4
Night Clean-up = 0
Office / Finish Tech = 1Of the 55, 16 were Slip / Trip / Falls
6 was Electrical Exposure11 were Scratch / Scrape / Bumps
1 were Emergency Equipment / Exit0 were Chem. / Debris Exposure8 were Lacerations/ Contusions8 were Sprains / Strains0 were Pinch Point2 were Burns3 were Explosion / Flash Backs
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6S Meeting Attendance Sheet:
Date: Date: Date: Date:DST Rep. Owner Team Member 6S Areas 1/7/2015 1/14/2015 1/21/2015 1/28/2015
Judi B. Jerry S. Roxanna Area 1 Wood Frame Assy - Finish
Stan E. Steve O. Becky F. / Judy V. Area 1 Wood UPH
Don D. Slaton M. / Tony L. Henry C./ Terry V. Area 1 N/W UPH
Mike S. JD P. Gerald N. Area 2 Frame Assy - Finish
Mel S. Jason C. / Carrie B. Donna M. Area 3 Machine-Finish
Mark V. Josh D. Samantha Area 3 UPH
Bart W. Chris B. Lori M. / Roger Cutting Group
Kay H. Keith C. Lee S. Maintenance
Doug S. Chris C. Ricky L. Area 2 UPH Vac.
Ron D. Cathy M. Sharon M. / Jeff W. Material Handling
Dave N. Aaron B. Mary Jane Area 1 Machine Room
Mel (optional)
Danny
Brandee Environmental
Shelly
= Attended
= Excused Absence
= No Show
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6S Performance TrackingNOF 11th Avenue
DST Rep.6S Area Owners Team Member 6S Areas 8/15/2014 9/15/2014 10/16/2014 11/13/2014 12/15/2014 1/12/2015
LAST 6 Audit
Average
Dave N. Aaron B. Mary Jane Area 1 Machine Room 4.6 4.4 4.4 3.6 4.5 4.3 4.3
Judi B. Jerry S. RoxannaArea 1 Wood Frame Assy - Finish 4.9 4.3 4.7 4.8 5 4.9 4.8
Stan E. Steve O Becky F/Judy V Area 1 Wood UPH 4.7 4.7 4.8 4.7 4.7 4.7 4.7
Don D. Slaton M. Terry V./Henry C. Area 1 N/W UPH 4.7 4.7 4.6 3.8 4.3 4.2 4.4
Bart W. Chris B. Lori M / Roger G Cutting Group 4.6 4.3 4 4.7 4.8 4.9 4.5
Mike S. JD P. Gerald N.Area 2 Frame Assy -Finish 4.8 4.8 4.9 4.9 5 4.8 4.9
Doug S. Chris C. Ricky L. Area 2 UPH 4.8 4.7 4.6 4.5 4.7 4.7 4.7
Mel S. Jason C. Donna M. Area 3 Machine-Finish 4.8 4.8 5 4.7 4.9 4.9 4.8
Mark V. Josh D. Samantha Area 3 UPH 4.8 4.8 4.8 4.8 4.5 4 4.6
Ron D. Cathy M. Sharon M./ Jeff W Material Handling 4.7 4.4 4.6 4.7 4.7 4.7 4.6
Kay H. Keith C. Lee S. Maintenance 4.7 4.2 3.6 4.5 4.6 4.5 4.4
Plant Average 4.7 4.6 4.5 4.5 4.7 4.6 4.6
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NOF 11th Avenue 2014 6S Corrective Action
NOF 11th AvenueGoal Met
2015 6S Corrective ActionGoal Not
Met
#Improvement Priority 2015 Jan Feb Mar April May June July Aug Sept Oct Nov Dec
2015 YTD
% Complete
1 Area 1 Machine Room Open items 3 0 0 0 0 0 0 0 0 0 0 0 3 100%Closed items 3 0 0 0 0 0 0 0 0 0 0 0 3
2 Area 1 Wood Frame Assy -Finish
Open items 2 0 0 0 0 0 0 0 0 0 0 0 2 100%Closed items 2 0 0 0 0 0 0 0 0 0 0 0 2
3 Area 1 Wood Uph Open items 11 0 0 0 0 0 0 0 0 0 0 0 11 100%Closed items 11 0 0 0 0 0 0 0 0 0 0 0 11
4 Area 1 N/W Uph Open items 4 0 0 0 0 0 0 0 0 0 0 0 4 100%Closed items 4 0 0 0 0 0 0 0 0 0 0 0 4
5 Cutting Group Open items 1 0 0 0 0 0 0 0 0 0 0 0 1 100%Closed items 1 0 0 0 0 0 0 0 0 0 0 0 1
6 Area 2 Frame Assy - Finish Open items 4 0 0 0 0 0 0 0 0 0 0 0 4 100%Closed items 4 0 0 0 0 0 0 0 0 0 0 0 4
7 Area 2 Uph Open items 1 0 0 0 0 0 0 0 0 0 0 0 1 100%Closed items 1 0 0 0 0 0 0 0 0 0 0 0 1
8 Area 3 Machine - Finish Open items 1 0 0 0 0 0 0 0 0 0 0 0 1 100%Closed items 1 0 0 0 0 0 0 0 0 0 0 0 1
9 Area 3 Uph Open items 2 0 0 0 0 0 0 0 0 0 0 0 2 100%Closed items 2 0 0 0 0 0 0 0 0 0 0 0 2
10 Material Handling Open items 4 0 0 0 0 0 0 0 0 0 0 0 4 100%Closed items 4 0 0 0 0 0 0 0 0 0 0 0 4
11 Maintenance Open items 2 0 0 0 0 0 0 0 0 0 0 0 2 100%Closed items 2 0 0 0 0 0 0 0 0 0 0 0 2
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Planning Matrix
Each site has a comprehensive matrix for planning and executing actions
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Employee Engagement and
Communication
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Communication starts when you arrive in the PARKING LOT
NNational Office Furniture SSafety Orientation
11th Avenue Jasper
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Behavior Based Safety Training
Rev January 10 2014
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Why BBS at NOF 11th Avenue?Our approach
• We want an INJURY FREE working environment for our people
• A big step is to have ‘all’ our employees to better understand Behavior Based Safety by becoming BBS Site Champions
Rev Dec 18, 2013
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BBS Site Champions
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INJURY CAUSATION
Injury
Condition Behavior
85% of all injuries statistically are caused by unsafe acts or behaviors
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What we have gained
A better understanding of the challenges relative to Behavioral Safety and ways to directly address those challenges
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BBS Refresher
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We can continue to eliminate injuries by each of us taking more responsibility for our
actions
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Injury
Free A text comes through the phone
TRIGGERING POINT
What could the BEHAVIORS be?
What ANTECEDENTS could prime the BEHAVIOR to pickup the phone?
What are possible CONSEQUENCES?
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Behavior Based Safety is about taking
PERSONAL RESPONSIBILITY
for your actions
Choosing the SAFE behavior over an UNSAFE behavior (TRIGGERING)
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Hazard Recognition
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“Eliminate Exposures”
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HHierarchy of Controls
• AVOIDANCE
• ENGINEERING
• ADMINISTRATIVE• PERSONAL PROTECTIVE
EQUIPMENT
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• Every operation, process and or piece of equipment in Kimball International must have a Job Hazard Analysis performed to find and eliminate the exposures of the job
JOB HAZARD ANALYSIS
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Near Miss Program
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Near Miss Program
• With low or no injuries, there is not enough data to trend our challenges and opportunities.
• Gathering near miss data, provides the data needed to trend and implement risk mitigation measures
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Safety Shirt Wednesday
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Early Intervention Program
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Early Intervention
Early
Late
90+% xxxx%
EARLY reporting can provide success eliminating pain (and surgical intervention)
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# total Early Intervention11th January-June 5411th July-December 67
BY JOB Upholsterer Handsander AssemblyFinish Spray Cutting Machine Room
Final Inspect Mat. Hand. Sew
Maintenance Office
Sand/inspect U.V. Final assy. Pack Trim/pack Team Lead Build
11th January-June 13 9 2 6 4 4 4 2 1 1 811th July-December 29 3 7 7 2 3 0 3 1 4 3 1 0 0 1 0 3 0
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Full Court Press Progress tracking
Item 11thSafety Observation Audit
Daily checklist for higher risk equipmentHazard Recognition training for front line leaders
Small group meetings, injury reportingIncreased time on the shop floor by safety
Full Court Press
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NOF Daily Safety Observation Audit
Area:
Department:
Auditor:
Process Item
The employee appears to be working ergonomically correct (not in an awkward position)
There are no slipping or tripping hazards present
Verify the employee has been properly trained for the job
A job safety procedure is posted at the workstation
The employees hands are not in the 'line of fire' or 'danger zone' when working (within 6" of the point of operation)
The employee states there are no hazards or potential items that need corrected or improved
Hand tools are correct for the job and in good condition, including staple guns and pinners
The correct PPE is being used on the operation (glasses, gloves, foot protection, etc)
The employee performed their stretches today
All guards are in place and adjusted properly not to allow contact with the point of operation
The employee knows the emergency alerts and actions
The employee stays under the 40 lbs lifting restriction
The area is clean and organized to prevent injuries
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10 7 73 2
69
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34
83
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Ergo issues
'Lifting required over 40lbs
'Housekeeping or organization lacking
'Guarding inadequate or improperly
adjusted
'Not fam
iliar with em
ergency alerts andactions
'Slip or trip hazards
'Stretches not performed consistently
'Improper hand tools
'Employee not trained
'JSP not posted
'Employee perceived hazards
'Hands in the danger zone
'PPE issues
11th Avenue
11th Avenue, 775
Danville, 210
Fordsville, 131
Santa Claus, 139
Audits
223 actions in 2014
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Free
Daily Startup Meeting
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• Area 1 • Area 2• Area 3• Maintenance • Area 1 Wood• Material Handlers
Daily Startup Meetings
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Daily Safety Matters
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National Office Furniture Jasper 11th Avenue2014 Safety Improvements
• Near misses = 500+
• Safety Team findings and audits = 300+
• Safety Observation actions = 223
• Ergonomic improvements = 42---------------------------------------------------------
“1000” + safety improvements in 2014
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Free
National Office Furniture Jasper 11th Avenue
