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Safety Dynamics for Enhanced Productivity

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  • 1. Safety Dynamics for Enhanced Productivity Mike Douglas, General Motors Senior Manager Global Safety New Technologies & Standards .Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
  • 2. History of Significant Events1992 Consolidation of all safety items over many specifications into one document1996 Created the concept of Task Based Risk Assessment (TaBRA) How we Quantified Productivity gains NI= SP*U-[(VC*U)+FC] 1998 Created Standardized Work – Integrated Process 2005 Created the 2-Stage Approach (Hierarchy of Controls) 2008 Created the Risk Assessment Worksheet
  • 3. The Continuums The Continuums Enablers of Confidence and Creditability
  • 4. The Continuums The ContinuumsThe Continuums create a Visual ImageHelp your “dialogue(s)” to be more:• fluid• effortless• spontaneous
  • 5. Eleven Continuums • Specificity • Reality • Perception of • Platform Safety • Technology • Income • Safety Hierarchy • Comprehension • Engineering • Outcome Controls • Responsibility
  • 6. Specificity Continuum General SpecificPrinciples Details What‟s in it for them
  • 7. Perception of Safety Legal Cost of Injuries Safety is a Top Safety is aWhat is Safety Compliance Priority Value „ Discipline / Compliance Self Assessment Data Focus Cultural Focus Focus
  • 8. Income ContinuumLosses Net Income = 0 Gains Contribution Margin < 0 Contribution Margin < 0NI = (Sp – Vc)#U – FC
  • 9. Bottom Line Results4 Trucks / day times 5 Plants times Contribution Margin = 3.8 Million $ per year 2 Trucks Every 5 hours Analyzing Details of Safety Productivity” NI = (Sp – Vc)#U – FC Applying new technologies reduces Manufacturing costs (Capital investment,NI – Net Income Maintenance techniquesSp – Selling Price etc…)Vc – Variable CostU – UnitsFC - Fixed Cost
  • 10. Reduction in Fixed Cost 1997 2000 2005 2010 2012Installation Costs 700 P Relays Safety Relays GuardLogix® Compact GuardLogix SmartGuard™ 600 PowerFlex® 755 with Safe Off
  • 11. Comprehension ContinuumEasy Difficult Migrate based on dynamics of culture
  • 12. Outcome ContinuumQualitative Quantitative Migrate or “Balance” based on dynamics of the Marketplace
  • 13. Responsibility ContinuumNo Responsibility Complete Responsibility Migrate or “Balance” based on dynamics who will benefit
  • 14. Reality ContinuumCombative Competitive Cooperative Collaborative
  • 15. Platform ContinuumFace to Face Voice Text Web
  • 16. The Technology (Tech) ContinuumAverse Apathetic Open Savvy Manual Checklist Power Point Excel Tool
  • 17. The Safety HierarchyType of Standards“A” Level“B” Level Hierarchy of Controls“C” Level “Balance” Movement along the continuum
  • 18. Hierarchy of Controls Safe Operating Personnel Engineering Awareness Procedures ProtectiveEliminate Substitute Controls Devices Training Equipment Elimination part of a Combinations of these are the outcomes of the mitigation part of a Risk Risk Assessment Assessment
  • 19. Engineering Controls TR-6 Section 4.13 En 954 ANSI TR-6 13849-1 Table 6 13849-1 13849-1Categories Circuit Examples 13849-1 Figure 5 Performance Levels Performance LevelsB,1,2,3 & 4 Circuit Analysis Tables ANSI B11.0 (TR-3) Hardware Software 1996 2006 2011 FIRM MPS SCS
  • 20. The Eleven Continuums Support GM’s“Design Build and Sell the World’s Best Vehicles” Design Build and Sell
  • 21. The World’s Best VehiclesCopyright © 2011 Rockwell Automation, Inc. All rights reserved.
  • 22. Questions?Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

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