Our company’s mission is to help industrial workers return home safely from the job every day. So it’s even more imperative that we practice what we preach and ensure that our own safety practices meet or exceed industry best practices.
Our own Quality Engineer and Safety Manager George Biggs shares some of his team’s best practices that are keeping workers safe and have contributed to their year-to-date record of zero lost time accidents. His plant manufactures SafeRack, ErectaStep, RollaStep and YellowGate brand fall protection and access systems for industrial work areas.
Assessments are effective in determining where potential safety risk lies. They provide an overall view of plant safety and identify specific improvement areas. It should be noted that safety assessments are not a substitute for daily awareness of work conditions, and applying the “see something say something” philosophy to immediately correct a hazard. (See “Weekly Safety Audit” below.)
“Often we grow accustomed to our work environment and aren’t aware of some of the less obvious safety issues. Assessments give us a closer look. They ensure that safety risks are properly addressed,” said Biggs.
Weekly safety audit and toolbox meeting
The weekly safety audit ensures that the gains from the safety assessment are maintained and identifies any new safety issues since the last assessment was conducted. Weekly toolbox meetings are brief and less formal, but an effective way to handle quick-fix safety issues or escalate them if required. They’re also good opportunities to identify worker safety training or refresher training that may be needed.
The following infographic was based on data from a SafetyToolboxTalks survey taken July 16, 2014.
Integrate safety into production meetings
Production meetings provide another forum to raise awareness of safety. Often safety issues affect production. The resolution to some safety issues can result in productivity increases. We see this in our own business. Our worker access and fall protection systems enable workers to move more freely and with confidence knowing they’re protected. The result is greater productivity.
Borrowed from Toyota, visual boards increase awareness of safety and encourage safety each day. The board consists of nine safety elements:
- Green cross - The goal is to have a green cross at the end of the month and the board gives employees a visual reminder of their progress. Yellow blocks indicate a medical incident and red blocks a lost time accident.
- SafeRack PPE Person – Interjecting a little humor, PPE Person reminds workers what personal protective equipment is required.
- Employee safety pie chart – Each employee has the opportunity to place his or her safety issue/information on a slice of the pie.
- List of near misses – This serves as a reminder to avoid future potential safety issues or incidents.
- List of accidents – Identifies a safety issue that must be addressed
- Wellness newsletters and general safety information
- Ergonomics and ventilation – provides tips on reducing strain and sprain injury and lets workers know what’s being done to improve the overall work environment.
- TRR – Total Recordable Rate indicates progress toward a zero-incident workplace
- Egress Map
Hands-on Safety Training
This is a highly effective method for teaching and reinforcing safety practices on the job. “I bring real-world examples to the training,” said Biggs. “At the end of each training session, I asked questions about the previous training session to reinforce learning. I also use funny cartoons, which I find makes the training more engaging and the lesson more memorable.”
Going Green for Safety
Green initiatives can provide a new perspective on safety and reducing potential hazards. “Our safety team is currently working on going green by removing all non-desirable cleaning chemicals and replacing them with employee- and environmentally-friendly solutions,” said Biggs.SafeRack "Green Team" from left to right: George Biggs, Jimmy Collins, Scott Fisher, Dustin Cox and David Garner (absent).
2 Operators on Machinery
Some of the most serious and often fatal industrial accidents occur when machine operators are alone. By the time the first call for help is heard, it’s often too late when it comes to fast moving machinery. A team of two workers when operating machinery prevents a malfunction or operator error from becoming a serious accident.
A true story...
“In a previous company, our rule was to always have two people when working on machinery and never let a person work on a machine alone. There was a large mill on the end of my line. It had stopped, and we couldn’t get it started. I called maintenance and they sent an experienced person who told me I didn’t need to stay, but it was our policy to have two people present, so I stayed anyway. The technician got down in the machine and when he made the limit switch, the mill started. He had nowhere to go. I hit the emergency switch and killed the power, but the mill continued turning with just the power from the weight of the mill. The technician’s coveralls became entangled in the blade. Fortunately, he wasn’t hurt, but it was a very close call.
Safety rules are in place for a reason. Ensure that everyone follows them. Look at your hazard assessments, apply safety principles, and above all, involve everyone in safety to avoid near misses or worse.”
Give us a call to help assess any safety or fall protection hazards. 866-761-7225.