Contract flow down requirements are necessitating that Tier-1 Automotive suppliers be compliant with ISO 18001. Central to this safety management system is the emphasis on identification and control of risk, performance improvement and sustainability. The program’s goal is to look for ways to elevate the safety performance focus beyond simply measuring injuries and analyzing how safety impacts productivity. One supplier successfully implementing this approach said, “Our work over the past year with the PM Vitals’ Safety Indicators has been a vital component to reducing workplace hazards and improving the bottom line.”
Keeping Up Is Not Getting Ahead
Major automotive suppliers are currently experiencing rapid growth in North America. The region is dotted with new, state-of- the-art plants, where hiring 1,000-2,000 additional workers presents a bevy of challenges. One company with a relatively new plant realized safety was not measuring up to their expectations. After two years of operation, the safety program was overwhelmed with administrative duties, reporting and ad hoc communications around workplace injuries. Analysis of the underlying causes of these injuries, including preventative measures for future hazard reduction, fell by the wayside.
The Right Tool Gets The Job Done
Year-over- year comparison covering over five million exposure hours at the facility identified the ability to evaluate and distill Injuries and Events into the Safety Indicators platform. The effectiveness of the customized set of metrics and Corrective Actions on the safety culture led to a noticeable step change.
Our work over the past year with PM Vitals’ Safety Indicators has been a vital component to reducing workplace hazards and improving the bottom line.
Up Close & Personal
The PM Vitals platform easily configured to match the processes, which allowed the studied EHS programs to get the most from the tools. Supervisors and managers were trained to effectively document injuries, near misses and observations in a uniform manner. This new safety process both captured data and improved communication site-wide, translating into better understanding of safety incidents and trends. Using the Safety Indicators platform, year-to- year reduction in injuries between 2015 and 2016 exceeded 60%.
Better To Be Proactive Than Reactive
The Safety Team’s workload changed from “firefighting” to more proactive forms of safety management. Safety Indicators allowed the team in 2016 to focus on capturing actionable data from injuries and audits and find trends and improve Corrective Action. Our safety improvement strategy anticipated a 50% improvement, which was easily surpassed. The efficiency created by Safety Indicators has allowed our 2017 focus to be on increasing employee engagement and extending the observation program to the shop floor.
Safety Is Good Business
In the three programs within the study, the ROI on the investment in Safety Indicators has been clear. In one case, the review of results in terms of hard savings on injury reduction was equivalent to the profit from the production of an additional 10,000 transmissions — and that is before taking into account insurance premium reductions!