Presentation on theme: "Milliken’s Safety Processes"— Presentation transcript:
1 Milliken’s Safety Processes Wayne PunchDirector Emeritus, Safety / Security Milliken & CompanyBeing a new team leader can be a little scary, especially at first, so this first lesson looks at how your role is changing from regular production associate to one with new responsibilities and what you need to remember as you transition into this role...(CLICK)
3 A Customized System of cultural safety consciousness that Milliken Safety Way SystemA Customized System of cultural safety consciousness thatengages entire workforce, produces proactive focus, and utilizes continuous improvementfor an injury-free workplace.
4 Milliken & Company Safety Policy The safety and health of all its people is of primary importance to Milliken & Company. Milliken will devote resources to train its people to perform their jobs safely, to insure equipment can be operated in a safe manner, to eliminate workplace hazards and to comply with applicable safety and health laws and regulations. Milliken believes that all injuries are preventable, all health risks are controllable and that management is accountable.ChairmanMilliken & Company
5 Continuous Improvement Evolution of the Milliken Safety Process1985Transition to Associate-Led TeamsREACTIVE1990Leadership Commitment , Involvement, Support1992Partnered with OSHA VPP Star – Associate Empowerment& CompliancePREVENTIVE1996Milliken Performance System2000Applied Continuous Improvement MethodologiesPREDICTIVE2005Focused on Hazard/Risk ReductionEquipmentConditionsBehaviorsContinuous ImprovementTODAY
6 An Industry-Wide Comparison Total Recordable Incidence RatesAn Industry-Wide Comparison
7 Common Safety Practice Driven From the Top DownSafety Operations Strategy Developed at Corporate LevelGeneric Initiatives are Directed to SitesOwnership and Emphasis has VariationImplementation has VariationManagement Control ImpedesInvolvement and InteractionEmployeeDisconnectLack of Individual andGroup CommitmentConsequenceDrivenProcessLimited Results
8 Continuous Improvement A New Safety StrategyContinuous ImprovementEmployee EngagementPreventive / Predictive Driven ProcessKnowledge & AwarenessIndividual DevelopmentSub-Committee DevelopmentSteering Team DevelopmentLeadership Development and Support
10 Key Components of the Safety Process EducationResourcesMission / VisionEmpowerment &CommitmentPositive Process
11 Key Components of the Safety Process EducationPeer To PeerFirst Aid/C.P.R.ResourcesExerciseWellnessSocialNo SmokingBenchmarkStressMission / VisionHealth RiskDietEmpowerment &CommitmentProtective EquipmentProceduresPositive ProcessE.R.T.TechnicalMethodsBenchmarkFirst Aid/C.P.R.
12 Organizational Structure Key Components of the Safety ProcessOrganizational StructureEducationTeamsInvolvementResourcesManagersHospitalTimeMission / VisionDHECHighway PatrolCommunityWildlifeEmpowerment &CommitmentFire Dept.SpaceCo. ExtensionPositive ProcessVideoInformationPublicationsBudgetMaterialTools
13 Continuous Improvement Key Components of the Safety ProcessEducationProcessPlanningResourceResourcesStrategyRecognitionEducationPOEMission / VisionProcessGoalsResultsEmpowerment &CommitmentAuditsMeasurementFeedbackSurveysPositive ProcessWhole PersonPurposeInteractionContinuous ImprovementExpectations
14 Stop Unsafe Acts or Conditions Key Components of the Safety ProcessEducationRulesTeamworkResourcesPolicyCounselAuthorityMission / VisionScheduleStop Unsafe Acts or ConditionsResponsibilityEmpowerment &CommitmentAccountabilityPositive ProcessCommitmentConsistency
15 Key Components of the Safety Process EducationIndividualRecognitionTeamResourcesPlantFreedom to TryMission / VisionTrustEmpowerment &CommitmentFun/InterestingPositive ProcessStructureTeams
16 The Journey to World Class Performance Standardized Daily Management SystemModels, Common LanguageStandardized Problem-Solving ApproachStandardized Education ProcessConsistent Measurement ProcessEmpowered and Engaged Associates
17 How Do You Empower People ? Give employees the tools they need to lead the safety process (education, time, resources, etc).Leadership must serve as sponsors - make yourself available!Communicate well with the team. Do not shoot the messenger.4. Support their ideas. Everyone deserves to be heard!Understand that SAFETY should be integrated into the organization’s daily functions.
18 How Do You Measure Involvement? To calculate % employee involvement, at least one of the following criteria must be met:serve as a Steering Committee memberserve as a Sub-Committee memberperform diagnosis / audits (equipment & conditions)train / educate other employees in safetyserve as a safety team leaderperform observations (behavior)be involved in a hazard reduction process
19 What do you really measure? How Do You Measure Involvement?What do you really measure?Does it have the ability to drive your process towards zero incidents?
20 Key Components of System Safety Way Process: How It WorksKey Components of SystemCommitmentZero ThinkingOrganizational AlignmentChange ReadinessValue DrivenCorporate GuidelinesSite AssessmentsStrategic PlanningMulti-level CommunicationMeasuresEducationActivitiesAuditsAnalysis
21 Key Components of System Safety Way Process: How It WorksKey Components of SystemCommitmentGap AnalysisVerify the TasksLeading and Lagging IndicatorsScoreboardsBusiness CaseSurveysObservationCommittee ReviewsMeasuresEducationActivitiesAuditsAnalysis
22 Key Components of System Safety Way Process: How It WorksKey Components of SystemCommitmentTechnical & Soft SkillsBuild the ProcessIncorporate Compliance and StandardsMeasuresEducationActivitiesAuditsAnalysis
23 Key Components of System Safety Way Process: How It WorksKey Components of SystemCommitmentAwarenessEstablish Motivational MethodsProject ManagementOrganize and TrainMeasuresEducationActivitiesAuditsAnalysis
24 Key Components of System Safety Way Process: How It WorksKey Components of SystemCommitmentConditions & EquipmentBehavior ObservationsCausation ToolsBehavioral DevelopmentMeasuresEducationActivitiesAuditsAnalysis
25 Key Components of System Safety Way Process: How It WorksKey Components of SystemCommitmentIncident ProfilesJob Safety AnalysisRisk AssessmentsCorrectional MethodsMeasuresEducationActivitiesAuditsAnalysis
26 Roles and Responsibilities of a Safety Process ROLE in the Safety ProcessRESPONSIBILITY of each RoleEstablish Safety as a Value, Demonstrate Commitment to the JourneyLeadershipProvide the ‘Tools to Improve’, Sustain the GainsManagementEmployeesEmpower and Engage
27 Safety becomes an integral part of Safety as a Corporate ‘Value’ SystemSafety becomes an integral part ofCompany’s Operational Excellence Strategy