Metal Manufacturing Case Study
Background
A metal manufacturing company in the USA faced a specific significant challenge in maintaining a safe working environment for its employees concerning Powered Mobile Equipment (PME). The plant and yard areas had frequent incidents related to PME and other operational hazards. They sought the expertise of our consulting firm to address these specific issues.
Objectives
- Identify and mitigate PME-related hazards and risk in the plant and yard.
- Assess GAPS within their PME program.
- Improve overall safety culture and compliance with OHS PME regulations.
- Reduce incident rates and enhance employee well-being.
Methodology
Initial Assessment and Hazard Identification
Conducted a thorough site inspection to identify potential hazards associated with PME, and included but not limited to forklifts, front end loaders, straddle carriers, pot carriers, reach stackers, dozers, graders, industrial tractors, car pushers, light vehicles, heavy yard trucks and off site transportation trucks.
Reviewed incident reports and safety records to understand the frequency and nature of past incidents.
Reviewed maintenance records on PME to identify potential use / misuse issues and unreported damage.
Reviewed policies and procedures that affected PME utilization such as traffic plans, inspection and maintenance schedules, & training requirements and inclusions.
Risk Analysis and Prioritization
Performed a risk assessment to evaluate the severity and likelihood of identified hazards.
Prioritized risks based on their potential impact on employee safety and operational efficiency.
Development of Safety Improvement Plan
Created a detailed action plan to address high-priority risks as per the hierarchy of controls – elimination, engineering, administrative controls, and personal protective equipment (PPE) requirements. Some of the specific controls put in place was
- Replacement of equipment with better units better suited to the task
- Proximity detection and alert systems implementation,
- Implemented changes to visibility and lighting in specific areas
- Updated procedures for safe PME operation, maintenance, and inspection.
- Revision to the Traffic Management Plan with enhancement of signage and markings and speed control measures.
- Training upgrades
- Upgrades to a monitoring and reporting system, including technology
Implementation and Training
The implemented the safety improvement plan occurred in phases, starting with the most critical areas.
Conducted comprehensive training sessions for employees on safe PME operation, hazard recognition, and emergency response procedures.
Monitoring and Continuous Improvement
Established a monitoring system to track the effectiveness of implemented safety measures.
Conducted regular safety audits and reviews to ensure ongoing compliance and identify areas for further improvement.
Results
- Reduction in PME-Related Incidents
- Achieved a 40% reduction in PME-related incidents within the first six months of implementation.
- Achieved a 77% reduction in PME related equipment and property damage that would not have been reported.
- Improved employee awareness and adherence to safety protocols.
- Enhanced Safety Culture
- Fostered a proactive safety culture through continuous training and engagement.
- Increased reporting of near-misses and potential hazards, leading to timely interventions.
- Ensured compliance with relevant OHS regulations and standards.
- Received positive feedback from regulatory bodies during safety inspections.
