Lean Safety

Transforming your Safety Culture with Lean Management

Lean Safety

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.

Lean Safety Gemba Walks

A Methodology for Workforce Engagement and Culture Change

Lean Safety Gemba Walks

A Lean Safety Gemba Walk is a walk through the work area (Gemba) that focuses on the continuous improvement of safety. When conducted in a respectful manner, by skilled facilitators, Safety Gemba Walks can have a dramatic long-lasting impact on the culture of a business. Lean Safety Gemba Walks: A Methodology for Workforce Engagement and Culture Change is a follow-up to the author's bestselling book, Lean Safety, published in 2010. It is a natural progression from the philosophical overview provided by Lean Safety to the reality of the application of those principles in facilities around the world. This book presents a collection of Lean Safety Gemba Walk case studies that are based on the author’s experiences over the last four years. As the stories unfold, readers are transported on a journey of discovery through the Gemba and begin to see safety differently just as those who physically participated. Illustrating the importance of employee engagement and culture change, the book provides you with the tools to engage managers, employees, and hourly staff in the continuous improvement of safety. The concepts covered will allow you to empower employees to make a difference in their safety culture rather than simply complying with safety rules.

Lean Safety

Transforming Your Safety Culture with Lean Safety Management

Lean Safety

Jam packed with useful and practical advice for Safety Professionals and Safety Managers this book is full of useful tips and information including: Why Focus on Safety. Why Focus on Lean. Leadership. Changing the Safety Culture. Safety. Family. Empowerment. Engagement. Encouragement. Reward. Enthusiasm. Integrity. Determination. Generating Ideas. Stretch Targets. Safety Culture Survey. The Triple Vision. The New Triple Bottom Line. Focus on the things we can control. The Global Cost and Safety Curves. Business Drivers - Lean Focus. Elements of a Safety Management System. Safety Policy. Governance. Risk Management Framework. Take 5. Job Hazard Analysis (JHA or JSA). Risk Assessments. Effective Controls. Standard work instructions (SWI) / procedures. Bow Ties. The Golden Rules. Human Factors. Injury Management. Injury Reporting. Safety meetings / forums. Workforce Consultation. Document Control. Register of Compliance Obligations and Licenses. Change Management Process. Safety Cases. Contractor Management. Interface Coordination Plans (ICPs or Interface Agreements). Standards. Training and competency. Medicals / Health Assessments. Drug and Alcohol testing program. Fatigue Management. Emergency Management. Effective Supervision. Safety Values. Hazard Reporting. Field Leaderships and Safe Act Observations. Planned task Observations. Fatality Prevention Program. Critical Control Monitoring. Auditing. Key Performance Indicators (KPI's). Safety Management System Review. Accident and Incident Investigations. Corrective Actions. Significant Incident Learnings. Communications to and from the workforce. Lean Tools for Safety. The War Room (Lean Boards). The Art of Kaizen (PDCA). The Kaizen Blitz. Elimination of Waste (Muda). 5S. Human Factors (Poka-Yoke). The 5 Gemba Principles. The 5 Why's Technique. Quality Circles. Ishikawa diagrams. Idea Generation. A3 Problem-solving. Metrics. Lean Boards. Pareto Charts. Histograms. Taxonomies. Benchmarking. Robotics - the future.

The Routledge Companion to Lean Management

The Routledge Companion to Lean Management

Interest in the phenomenon known as "lean" has grown significantly in recent years. This is the first volume to provide an academically rigorous overview of the field of lean management, introducing the reader to the application of lean in diverse application areas, from the production floor to sales and marketing, from the automobile industry to academic institutions. The volume collects contributions from well-known lean experts and up-and-coming scholars from around the world. The chapters provide a detailed description of lean management across the manufacturing enterprise (supply chain, accounting, production, sales, IT etc.), and offer important perspectives for applying lean across different industries (construction, healthcare, logistics). The contributors address challenges and opportunities for future development in each of the lean application areas, concluding most chapters with a short case study to illustrate current best practice. The book is divided into three parts: The Lean Enterprise Lean across Industries A Lean World. This handbook is an excellent resource for business and management students as well as any academics, scholars, practitioners, and consultants interested in the "lean world."

On the Practice of Safety

On the Practice of Safety

Explains how to implement the best safety practices and why they work Reviews from the Third Edition "An excellent piece of work." —Safety Health Practitioner (SHP) "A useful fountain of knowledge." —Quality World "This is a book to be read now for its educational value and also to be kept on the shelf for easy future reference." —Chemistry International The Fourth Edition of On the Practice of Safety makes it possible for readers to master all the core subjects and practices that today's safety professionals need to know in order to provide optimal protection for their organizations' property and personnel. Like the previous editions, each chapter is a self-contained unit, making it easy for readers to focus on select topics of interest. Thoroughly revised and updated, this Fourth Edition reflects the latest research and safety practice standards. For example, author Fred Manuele has revised the design chapters to reflect the recently adopted American National Standard on Prevention through Design. In addition, readers will find new chapters dedicated to: Management of change and pre-job planning Indirect-to-direct accident cost ratios Leading and lagging indicators Opportunities for safety professionals to apply lean concepts Role of safety professionals in implementing sustainability Financial management concepts and practices that safety professionals should know Many chapters are highly thought-provoking, questioning long-accepted concepts in the interest of advancing and improving the professional practice of safety. Acclaimed by both students and instructors, On the Practice of Safety is a core textbook for both undergraduate and graduate degree programs in safety. Safety professionals should also refer to the text in order to update and improve their safety skills and knowledge.

Safety Performance in a Lean Environment

A Guide to Building Safety into a Process

Safety Performance in a Lean Environment

As changing customer demands and shifting world markets continue to put a strain on businesses in all sectors, your business needs every advantage to stay competitive. Many people may think of Lean processes as suitable only for the manufacturing floor, but that couldn’t be further from the truth. Safety Performance in a Lean Environment: A Guide to Building Safety into a Process demonstrates how Lean tools can eliminate waste in your safety program, making it an important piece not only in keeping your organization safe but also in keeping it globally competitive. Written by safety pro Paul F. English, this book explores tools such as Lean manufacturing, DMAIC processes, and Kepner-Trego problem solving and how to use them to increase efficiency and eliminate waste in safety programs. He goes on to discuss value-based management, a technique identified as a leading business model for any organization wanting to catch "The Toyota Way." These processes help you build, incorporate, and sustain a safety program and understand how to get and maintain a foothold for the safety program in times of change. Here’s what you get: Real safety solutions for a Lean environment Methods for setting up standard work for EHS professionals How-tos for JSA and pre-task analysis to help develop standardized work Tips and tricks that everyone can use to jump start a stalled safety program No book currently on the market discusses Lean manufacturing or Six Sigma processes and links them to the occupational safety or environmental science. Yet these are the areas where the need for Lean processes is becoming acute. English demonstrates how to anticipate paradigm shifts in management models and how environmental health and safety fits into the model. He defines what adds value to the safety and manufacturing process as well as to the customer. These changes may include a change in daily, weekly or monthly metrics that can help or harm a safety program. Defining what adds value to the safety and manufacturing process and the customer helps you understand how to build safety into a process, creating a strong safety program.

Lean Behavioral Health

The Kings County Hospital Story

Lean Behavioral Health

Lean Behavioral Health: The Kings County Hospital Story is the first lean book that focuses entirely on behavioral health. Using the principles of the Toyota Production System, or lean, the contributors in this groundbreaking volume share their experience in transforming a major safety net public hospital after a tragic and internationally publicized event. As the largest municipal hospital system in the United States, the New York City Health & Hospitals Corporation adopted lean as the transformational approach for all of its hospitals and clinics. Kings County Hospital Center, one of the largest providers of behavioral health care in the country, continues on its transformational journey utilizing lean's techniques. While not every event was fully successful, most were and every event, including failures, increased the knowledge base about how to continually improve quality and safety. Having made major changes, Kings County Hospital Center is now recognized as a center for transformation and quality receiving high marks from oversight agencies. This volume begins by describing the basic principles of the lean approach-adding value, eliminating waste, and tapping the organization's line staff to create and sustain dramatic change. An overview of the use of lean from a quality improvement perspective follows. Lean tools are applied to many services that comprise the behavioral health value stream and these stories are highlighted. The experts in identifying waste and adding value are the line staff whose voices are captured in the clinical chapters. Insights learned by event participants are emphasized as teaching points to provide context for what has worked or has not worked at Kings County Hospital Center. While the burning platform at Kings County Hospital Center was white hot and while the Department of Justice scrutinized its quality of patient care, the application of lean methods and tools has transformed the hospital into a potential model for behavioral health programs facing the challenges of the present healthcare environment. It is a must-have story for clinicians, administrators and other leaders in the mental health field devoted to improving quality and safety at their hospitals and clinics.

Lean Culture for the Construction Industry

Building Responsible and Committed Project Teams

Lean Culture for the Construction Industry

Given that the greatest risk factor on any project is manpower costs, problems resulting in delays, rework, or overtime will lower profits through increased labor costs. Most of these process-generated costs are fully preventable. An in-depth exploration of the application of Lean initiatives in the construction industry, Lean Culture for the Const

Lean Sustainability

Creating Safe, Enduring, and Profitable Operations

Lean Sustainability

The Japan Institute of Plant Maintenance defines safety as the maintenance of peace of mind. Without peace of mind, or the serenity brought about by a safe working environment, employees will be unwilling and even unable to focus their energies on production improvement. Thus, it can be said that all improvement begins with safety. Winner of a 2013 Shingo Research and Professional Publication Award! A how-to manual on the proper integration of safety and environmental sustainability with Lean implementations, Lean Sustainability: Creating Safe, Enduring, and Profitable Operations provides a proven recipe for achieving safety and sustainability excellence. This book is the result of the author’s two decades of experience implementing Lean; Safety, Health, and Environmental (SHE); and sustainability processes in the chemical, food, and consumer products industries. It unveils valuable lessons learned and little-known tips for eliminating waste and increasing process efficiency—while reducing safety incidents and the overall impact on the environment. The text illustrates how to use the SHE Pillar as a gateway to continuous improvement, regardless of the improvement methodology you use. Bolstered with proven methodologies and real-world advice, it introduces novel approaches for achieving safety and sustainability excellence, including: Autonomous Safety—supplying employees with the knowledge, skills, and motivation to work safely Triple Zero—the achievement of zero accidents, zero environmental incidents, and zero losses Green Value Stream Mapping—the application of Value Stream Mapping to environmental and sustainability issues Although there are many books on Lean, sustainability, and SHE, few explain how to integrate these dynamic tools. Walking you through this process, this book supplies the tools to create a synergy that will boost efficiencies across all segments of your business. Follow its advice and you’ll be on your way to making your organization and employees Lean, green, and serene.

Occupational Health and Safety Management

A Practical Approach, Third Edition

Occupational Health and Safety Management

Reflecting changes in the current health and safety landscape, Occupational Health and Safety Management: A Practical Approach, Third Edition includes examples and tools to facilitate development and implementation of a safety and health management approach. This how-to book is not just an information providing text. It shows you how to write a program and identify hazards as well as involve workers and attain their cooperation. It emphasizes the need for better and more effective communication regarding safety and health. See What’s New in the Third Edition: Chapters on workers’ compensation, terrorism, and Lean safety/sustainability Additional coverage of flammable liquids and ventilation, accident reporting, and accident investigation New compliance requirements as well as expanded accident investigation, environmental, and risk analysis guidelines PowerPoint presentation slides for each chapter A complete and practical guide for the development and management of occupational safety and health programs in any industry setting, the book supplies a management blueprint that can be used for occupational safety and health in any organization, from the smallest to the largest, beginning to develop or wanting to improve its safety and health approach. It includes comprehensive guidelines for development of occupational health and safety programs to a variety of industries and is especially useful for start-up companies. The author takes a total management approach to the development of written programs, the identification of hazards, the mitigation of hazards by the use of common safety and health tools, the development of a safe workforce through communications, motivational techniques, involvement, and training. He addresses the tracking and acceptable risk from both safety and health hazards. He also discusses how to work with and within the OSHA compliance approach as well as how to deal with the OSHA regulations, workers’ compensation, terrorism, and Lean safety. As you understand and apply the guidelines in each chapter, you can put your company on the way toward building a successful and effective safety and health effort for its employers and employees.