Lean Safety: Transforming your Safety Culture with Lean Management

While worker safety is often touted as a company’s first priority, more often than not, safety activity is driven by compliance to legislation rather than any safety improvement initiative. Lean takes a proactive approach – it is not contingent on legislation. A serious Lean effort will tear apart an old inefficient entitlement-riddled culture and build it into something effective. Lean Safety: Transforming your Safety Culture with Lean Management takes lessons learned from Lean and applies them to the building of a world-class safety-first organization. Based on 30 years of experience with successful implementation of continuous improvement, Robert Hafey focuses the power of Lean improvement on the universal topic of safety. In doing so, he shows how Lean and safety are linked; that the achievement of one is often dependent upon achievement of the other. In this book, written for managers and executives as well as workers on the line, Hafey: Challenges each stakeholder to think proactively and accept individual responsibility for safety Emphasizes that the building of a top safety program requires the building of a world-class safety culture Demonstrates how basic Lean tools are as applicable to safety as they are to Lean, such as the A3 problem-solving process and the facilitated kaizen blitz Removes fear from the accident investigation process so that root causes are addressed rather than hidden Establishes standards and metrics for safety management that are clearly definable and measurable Any lasting improvement must become both institutionalized and perpetually capable of adaptation. World class safety is not about writing correct rules, but more about righting the culture responsible for the well-being of its stakeholders. Listen to what Robert Hafey has to say about Lean Safety.

Table of Contents:
Introduction Message for Leaders Message for Lean Thinkers Message for Hourly Safety Team Members Brief Overview of Chapters Why Focus on Safety? Demonstrate That Safety Really Is First Quick Guide: Lean Focused Approach to Safety Management Endnotes Change the Culture A Common Goal of Both Lean Philosophy and Safety Programs Quick Guide: Change the Culture Leadership’s Role Focus Everyone on the Process Quick Guide: Leadership’s Role Lean Tools for Safety You Can Continuously Cope or You Can Continuously Improve—The Choice Is Yours Lean Tool 5S: A Structured Method of Workplace Organization Sort Set in Order Shine Standardize Sustain Disciplined Approach Necessary to Maintain Safety in the Workplace Lean Tool: Visual Factory Signage Charts Signaling Systems Process Mapping Lean Tool: Training Lean Tool: Poka-Yoke (Failsafe) Lean Tool: Benchmarking Lean Tool: Continuous Flow/Cycle Time Gains Lean Tool: Standard Work Lean Tool: Problem Solving Lean Tool: Metrics Lean Tool: Teams Quick Guide: Lean Tools for Safety Endnotes Advanced Lean Tools for Safety Facilitated Leadership: Changing How People Think Lean Tool: A3 Problem Solving Step 1: State the Agreed Upon Problem or Need Step 2: Draw the Current State Map or State the Current Condition Step 3: Problem Solving—Use Ask "Why" Five Times Technique to Get to Root Causes Step 4: The Future State—Draw a Map or Describe HowYou Would Like It to Be Step 5: Implementation Plan Step 6: Audit Expected Results Against Actual Results Lean Tool: Kaizen Blitz Planning the Kaizen Event Facilitating the Kaizen Blitz Kaizen Team Presentation Kaizen Event Follow-Up Meeting Quick Guide: Advanced Lean Tools for Safety Endnote Safety Program Leadership It Doesn’t Have to Be a Manager Team Leader Management Facilitator Accident Investigation Facilitator Recorder Keeper Subteam Leaders Human Resources (HR) Facilitator Safety Walk Co-Coordinator OSHA Knowledge Expert Training Coordinator Quick Guide: Safety Program Leadership Endnote Incident/Accident Investigation Getting to Root Causes and Lasting Solutions Focus on Process, not People Getting to Root Cause and Corrective Actions Quick Guide: Lean Approach to Incident and Accident Investigations Promoting Safety Engaging Employees to Build Safety Awareness Flash Meetings Benchmarking (A Standard against Which Something Can Be Measured or Assessed) Safety Improvement Programs Safety Observation Program Job Safety Analysis Safety Kaizen Blitz Events Quick Guide: Lean Approach to Internal Safety Promotion Roadmap to World-Class Safety Pulling the Pieces Together to Build or Rebuild a Safety Program Safety Program Leadership Lean Approach to Safety Program Leadership Safety Team Lean Approach to a Safety Team Other Team Building Opportunities Recordkeeping Lean Approach to Recordkeeping Safety Program Outline Documents Safety Education Lean Approach to Safety Education Safety Program Activity Management Lean Approach to Safety Program Activity Management Safety Rule Definition. Lean Approach to Safety Rule Definition Safety Communications Lean-Influenced Safety Communications Quick Guide: Roadmap to World-Class Safety Safety Standard Work Foundation of Continuous Improvement Quick Guide: Standard Work for Managers Endnote Safety Metrics What You Measure Makes a Difference Lean Approach to Safety Metrics Quick Guide: Metrics Conclusion Glossary Index About the Author

Review :
If the strength of your company is dependent on developing an exceptional workforce, then start where it matters most - providing the tools for a safe, efficient and involved employee group. This book can be the roadmap to get you there. -Jerry Paulson, retired president and CEO, Flexco This much-needed book provides real practical examples of how safety and Lean teams working on their own improvement journeys can come together and drive easier, cleaner, and safer work environments and practices for the employees of any business. -Dan McDonnell, Lean Initiative Manager, General Electric Transportation If the strength of your company is dependent on developing an exceptional workforce, then start where it matters most – providing the tools for a safe, efficient and involved employee group. This book can be the roadmap to get you there. —Jerry Paulson, retired president and CEO, Flexco This much-needed book provides real practical examples of how safety and Lean teams working on their own improvement journeys can come together and drive easier, cleaner, and safer work environments and practices for the employees of any business. —Dan McDonnell, Lean Initiative Manager, General Electric Transportation