Lean Safety Transforming your Safety Culture with Lean Management

Introduction
Message for Leaders
Message for Lean Thinkers
Message for Hourly Safety Team Members
Brief Overview of Chapters

Why Focus on Safety?
Demonstrate That Safety Really Is First
Quick Guide: Lean Focused Approach to Safety Management
Endnotes

Change the Culture
A Common Goal of Both Lean Philosophy and Safety Programs
Quick Guide: Change the Culture

Leadership’s Role
Focus Everyone on the Process
Quick Guide: Leadership’s Role

Lean Tools for Safety
You Can Continuously Cope or You Can Continuously Improve—The Choice Is Yours
Lean Tool 5S: A Structured Method of Workplace Organization
     Sort
     Set in Order
     Shine
     Standardize
     Sustain
Disciplined Approach Necessary to Maintain Safety in the Workplace
Lean Tool: Visual Factory
Signage
Charts
Signaling Systems
Process Mapping
Lean Tool: Training
Lean Tool: Poka-Yoke (Failsafe)
Lean Tool: Benchmarking
Lean Tool: Continuous Flow/Cycle Time Gains
Lean Tool: Standard Work
Lean Tool: Problem Solving
Lean Tool: Metrics
Lean Tool: Teams
Quick Guide: Lean Tools for Safety
Endnotes

Advanced Lean Tools for Safety
Facilitated Leadership: Changing How People Think
Lean Tool: A3 Problem Solving
     Step 1: State the Agreed Upon Problem or Need
     Step 2: Draw the Current State Map or State the Current Condition
     Step 3: Problem Solving—Use Ask "Why" Five Times Technique to Get to Root Causes
     Step 4: The Future State—Draw a Map or Describe HowYou Would Like It to Be
     Step 5: Implementation Plan
     Step 6: Audit Expected Results Against Actual Results
Lean Tool: Kaizen Blitz
Planning the Kaizen Event
Facilitating the Kaizen Blitz
Kaizen Team Presentation
Kaizen Event Follow-Up Meeting
Quick Guide: Advanced Lean Tools for Safety
Endnote

Safety Program Leadership
It Doesn’t Have to Be a Manager
Team Leader
Management Facilitator
Accident Investigation Facilitator
Recorder Keeper
Subteam Leaders
Human Resources (HR) Facilitator
Safety Walk Co-Coordinator
OSHA Knowledge Expert
Training Coordinator
Quick Guide: Safety Program Leadership
Endnote

Incident/Accident Investigation
Getting to Root Causes and Lasting Solutions
Focus on Process, not People
Getting to Root Cause and Corrective Actions
Quick Guide: Lean Approach to Incident and Accident Investigations

Promoting Safety
Engaging Employees to Build Safety Awareness
Flash Meetings
Benchmarking (A Standard against Which Something Can Be
Measured or Assessed)
Safety Improvement Programs
Safety Observation Program
Job Safety Analysis
Safety Kaizen Blitz Events
Quick Guide: Lean Approach to Internal Safety Promotion

Roadmap to World-Class Safety
Pulling the Pieces Together to Build or Rebuild a Safety Program
Safety Program Leadership
Lean Approach to Safety Program Leadership
Safety Team
Lean Approach to a Safety Team
Other Team Building Opportunities
Recordkeeping
Lean Approach to Recordkeeping
Safety Program Outline Documents
Safety Education
Lean Approach to Safety Education
Safety Program Activity Management
Lean Approach to Safety Program Activity Management
Safety Rule Definition.
Lean Approach to Safety Rule Definition
Safety Communications
Lean-Influenced Safety Communications
Quick Guide: Roadmap to World-Class Safety

Safety Standard Work
Foundation of Continuous Improvement
Quick Guide: Standard Work for Managers
Endnote

Safety Metrics
What You Measure Makes a Difference
Lean Approach to Safety Metrics
Quick Guide: Metrics

Conclusion

Glossary
Index
About the Author

Biography

Hafey, Robert

If the strength of your company is dependent on developing an exceptional workforce, then start where it matters most – providing the tools for a safe, efficient and involved employee group. This book can be the roadmap to get you there.
—Jerry Paulson, retired president and CEO, Flexco

This much-needed book provides real practical examples of how safety and Lean teams working on their own improvement journeys can come together and drive easier, cleaner, and safer work environments and practices for the employees of any business.
—Dan McDonnell, Lean Initiative Manager, General Electric Transportation