The document outlines a Six Sigma approach aimed at improving safety processes, focusing on reducing workplace injuries and associated costs through management commitment and employee participation. Key analysis tools include Pareto charts and cause-and-effect diagrams to identify major contributors to incidents and implement standardized safety practices. As a result, the average incident rate significantly decreased from 40 injuries annually to less than 5, demonstrating the effectiveness of the implemented corrective actions.

1. © IEA, Inc. 2008 USING SIX SIGMA TOOLS TO IMPROVE SAFETY PROCESSES

2. Agenda FMEA C &E

3. Overview of Six Sigma

4. Overview of Six Sigma To be successful a Six Sigma, approach needs: Management Commitment Employee Participation Planning Involve all Aspects of the Organization Based on Continuous Improvement Same basic principles as ANSI Z10 – Occupational Health and Safety Management Systems

5. Continuous Improvement

6. Define

7. Define – Case Study Objective – Improve overall safety performance. Recordable rate average 4.5 to 5 Annual workers compensation $2.5 million (average) Data Sources – Plant statistics, incident reports, workers compensation reports. Output – Team charter, EHS incident data by location

8. Safety Performance – Flat Line

9. Measure

10. Measure – Case Study

11. Measure – Key Thoughts

12. Analyze - Objectives

13. Pareto Charts – Other Examples Shift Injury Type Injury Cause Body Part Length of Employment Day of Week Tools Used Product Made Supervisor Plant/Work Cell Location Vehicle Type Task/Work Activity Worker Type

14. Analyze – Case Study First level pareto

15. Analyze – Case Study First level pareto Second level pareto

16. Analyze – Case Study Third Level Pareto defines the C&E. 2 nd Level – use the C&E subtitles: Man – Materials – Machines – Methods – Measurements - Environment

17. Paretos

18. C&E Diagram - Fishbone 5 Why’s

19. C&E Diagram

20. C&E – Case Study Man Training provided? Use of PPE? Use of knives? Machines Types of knives used? Other options? PPE requirements? Core Slabbers not used? Methods Cutting away from body? Why cutting plastics? Measurements What measurements impact the use of knives? Environment Heat play a role?

21. C&E Feeds FMEA Example

22. FMEA

23. FMEA Outcomes – Case Study Standardized utility knives – Martor Megasafe Standardized “J” knives Eliminated manual core slabbing Purchased core slabbing equipment Established Policies

24. Improve Objective Prioritize, plan, and test corrective actions. Eliminate defects through process/product redesign. Deploy effective corrective actions. Output Redesigned process. Collect date/measurements on effectiveness.

25. Improve – Case Study Tested variety of knives. ROI projections on core slabbing equipment. Implemented policies on core slabbing, knife usage, and PPE requirements.

26. Control Plan Sets in place – rules for future practices. Often impacts many areas of the organization: Operations, Purchasing, EHS Guidelines for each of these areas to follow Identifies measurements to determine if the control plan is successful or needs to be revisited. Sets accountabilities and timelines. Becomes policy or procedure.

27. Control Plan (continued) Policies on standardized knives. Purchasing not allowed to purchase alternatives. Policy on knife usage – disciplinary action for improper use. All old knives removed and discarded by a given date. Incident statistics used a measurement – knife related incidents went from 40 injuries per year to less than 5!

28. Continuous Improvement

29. Key Lessons/Best Practices Go through the steps – don’t let personal influences bias the process. Use a team approach to the tools. Establish assumptions up front as an organization. Cost Avoidance credit? ROI Criteria Solid Incident Investigations are critical. Follow-up and Review. Use the data to drive the process.

30. End Result Incident Rate – 1.8 average for FY07 Workers Compensation – Projected costs $823,000

31. Questions

32. Contact Info Email: [email_address] Phone: 507-281-6661 Cell: 507-884-6691 LinkedIn http://www.linkedin.com/in/timpuyleart