Using Safety to Drive Lean Implementation
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Using safety to drive lean implementation can help organizations gain competitive advantages through greater efficiency while eliminating waste. Implementing lean tools such as standard work, visual management, and empowering workers to stop production for safety issues can simultaneously make workplaces safer and more productive. Many actions that make work safer, such as error proofing equipment and processes, also make operations leaner. Viewing safety as a way to reduce costs from injuries and as a leading indicator of lean implementation can provide benefits across quality, production, and costs.
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Using Safety to Drive Lean Implementation
- 1. Using Safety To Drive Lean Implementation Phil La Duke O/E Learning Presents…
- 17. Thank You!
Notas do Editor
- There is a very fluid definition of Lean Manufacturing, but essentially lean boils down to a very basic definition: the purpose of Lean Manufacturing is to reduce cost by reducing process inefficiency.
- In the context of Lean Manufacturing, “safety” refers to the elimination of all waste associated with paying to hurt workers.
- Here is a quick list of the tools for achieving a more Lean Operation, and I will cover each of these independently.
- Elimination of Waste. Nobody sees worker injuries as value-add, but the fact, is injuries are just another form of “muda” or waste. Not only does a robust safety management process reduce all loss-incident waste by eliminating hazards, it instills a corporate discipline where waste is ferreted out and eliminated; spreading rapidly thereafter to other key business measurables. And since nobody thinks worker injuries represents money well spent, one can use the implementation of a safety management system to drive the internalization of lean principles
- Hazard investigation and incident investigation often identifies shortcomings in an organization’s Total Preventive Maintenance (TPM) programs. So basically, a good safety management system can drive TPM both proactively and reactively.
- Workers who are the most experienced doing a particular job are typically the most skilled at producing at optimum production and quality levels. If those workers are sidelined by injuries, less skilled workers are often enlisted to replace them. Implementing a strong Safety Management System ensures that the most skilled workers are able to stay on the job and maintain peak process capability.
- In my experience, Continuous Flow and pull systems are one of the most fiercely resisted lean practices, but if these concepts are presented as a response to worker fatigue and ergonomics this resistance is likely to break down. We have seen implementation of continuous flow greatly reduce the physical difficulty of a job while making it more efficient and safer.
- Problem Solving and Error Proofing are crucial parts of any viable Safety Management System. Error Proofing complements safety by eliminating hazards before someone is injured and problem solving helps to stren as a primary method of removing the possibility of injuries from the system by design. Mistakes
- Stop the Line Quality System. Not only should a lean manufacturing system provide a Stop the Line (Andon) quality system for production, but a Stop the Line safety system as well. While SafetyIMPACT! focuses on removing hazards before disrupting production is necessary, it also recognizes that common causes of variation create unforeseen “high-risk” hazards while the system is running, and that they should be identified and corrected before an injury occurs.
- Standard Work Instructions (SWIs) should identify the safest way to do a job. SWIs are invaluable in incident investigation. The first question I always ask when doing a safety indspection is Job Safety Analysis can be used to create SWIs
- A factory is visually managed when there are systems in place that enable anyone to immediately assess the current status of an operation or process at a glance, and real-time information and feedback regarding the plant status are provided. SafetyIMPACT! can enhance your Visual Management efforts by providing a clear and common understanding of safety goals and measures to everyone, whether owner, manager, operator, or visitor. Our proprietary, Web-enabled hazard database also provides the real-time data needed to populate balanced scorecards and scoreboards.
- Each workstation should not only have all the information and equipment for the worker to inspect and produce good quality parts but also to do so with optimal safety. All workers are empowered to identify and act on abnormal or “near hit” conditions within their work areas that may result in injury, and the organization can begin to use structured problem-solving processes to achieve in-station process control for safety as well as quality.
- What I would like you to do know is go back to your organization and take a look at your info