Start a lean manufacturing initiative by focusing on safety

Lean manufacturing can begin by focusing safety, according to Robert Hafey, president, RBH Consulting LLC. Hafey, speaking at IMTS - The International Manufacturing Technology Show 2010 conference, talked about “Transforming Your Safety Culture with Lean Management” and shared examples on integrating lean with safety.

09/21/2010


Robert Hafey, president, RBH Consulting, LLCThe easiest entry point to get going with a lean manufacturing initiative is to focus on safety, according to Robert Hafey, president, RBH Consulting LLC. Hafey, speaking at IMTS - The International Manufacturing Technology Show 2010 conference, talked about “Transforming Your Safety Culture with Lean Management.”

Lean and safety personnel, put on the same team, may begin with different goals – safety staff members usually have the most concern about any situation being out of regulatory compliance.

Those working on lean initiatives readily realize that customers are most important, Hafey said, which inverts the traditional hierarchical pyramid.

IMTSCommon focus for both groups, however, is people, best approached in a coaching, rather than directive, style of management. A coaching style, said Hafey, asks questions of team members, such as, “Tell me how...,” “What would you do if...,” and “Why is it....”

Hafey gave examples from his experiences to illustrate how to pull people into lean initiatives.

Involve those interested: A manager for a series of small cells in his manufacturing area had a passion for lean. “I asked his supervisor if he could work on lean initiatives for 30% of his time.” Within five months, Hafey said, the manager had transitioned to full-time on the lean team. Asked what the manager thought about working on lean efforts, compared to quality assurance, Hafey said the manager felt he was having a greater impact in helping people improve the business.

What percentage of employees feel they’re engaged in making difference? Audience members in the IMTS session guessed 3%, 10%, and 30%. A Gallop poll said 29% employees felt as if they make a difference, and 54% of respondents said they were not engaged, Hafey said.

Reach out to other teams and outside the company: Hafey, put in charge of coordinating a safety Kazan blitz, involved two team members from within the company, two from the state Workman’s Compensation group, and six from other companies in the area. Purpose of the event was to improve safety by 75% in three days. Though most people were confused about the methods and mission the first day, Hafey said, by the third day, they were engaged in safety, understood the value of lean, and had a grasp of lean terminology. Among work behaviors seen and corrected: A worker stapling the bottoms of 300 boxes; standing on toes on barrel to rake; pushing boxes down conveyer, and sticking a hand in a potentially hazardous area.

He added that the Workman’s Compensation representatives were particularly impressed. Hafey said the Workman’s Comp personnel noted they often return to plants three months later to find that a laundry list of concerns still would not be corrected. A Kazan blitz applied to safety immediately identified and corrected hazards, he said.

www.imts.org

www.leansafetybook.com/aboutRBH.html

- Also read:

IMTS 2010 coverage - links to all stories to date

Manufacturing: Get lean, flexible, and improve product flow

How to manufacture a 5S program for your facility

Lean and Green Becomes Lean and Safe


- Mark T. Hoske, Control Engineering, www.controleng.com, CFE Media, www.cfemedia.com.



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
World-class maintenance: The three keys to success - Deploy people, process and technology; 2016 Lubrication Guide; Why hydraulic systems get hot
Your leaks start here: Take a disciplined approach with your hydraulic system; U.S. presence at Hannover Messe a rousing success
Hannover Messe 2016: Taking hold of the future - Partner Country status spotlights U.S. manufacturing; Honoring manufacturing excellence: The 2015 Product of the Year Winners
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Improving flowmeter calibration; Selecting flowmeters for natural gas; Case study: Streamlining assembly systems using PC-based control; CLPM: Improving process efficiency, throughput
Putting COPS into context; Designing medium-voltage electrical systems; Planning and designing resilient, efficient data centers; The nine steps of designing generator fuel systems
Warehouse winter comfort: The HTHV solution; Cooling with natural gas; Plastics industry booming

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me