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1、TE Operating AdvantageSafetyLearning ObjectivesAt the completion of this course,you should be able to:Understand the core Safety ProgramsUnderstand the Star Level Requirements for SafetySafetyManufacturingInformation SystemsEngineeringLogisticsCommunicationsSales&MarketingProcurementFinanceHuman Res
2、ourcesLegalSafety is a core value with the goal to create an incident free working environment.Excellence in safety builds on safety programs,a foundation of compliance with management ownership,effective systems,risk assessment and mitigation,and varied opportunities for all employees to participat
3、e in the safety program.Think about|How will you foster a culture of safety,and provide opportunities for all employees to participate in safety?EXAMPLE|Successful and sustainable safety requires motivated employees who want to be part of the effort.Look for creative ways to get everyone involved:Be
4、havioral Based Safety(BBS)observers,safety project teams,safety promotional programs,ergonomics projects,safety trainer,and moreAgendaCore Safety ProgramsS.A.F.EErgonomicsMachine GuardingBehavioral Based SafetyStar Level Requirements SafetyAgendaCore Safety ProgramsS.A.F.EErgonomicsMachine GuardingB
5、ehavioral Based SafetyStar Level Requirements Safety -TEs leading safety metricManaging safety to reach our goal of zero injuries requires measuring the presence of safety,not simply injuries.The expectation is that each site will use S.A.F.E.to define where they currently are in comparison to best-
6、in-class safety management systems and then create a safety improvement strategy to improve their score.This assessment is designed to be a leading indicator of safety performance and measured by a web-based safety management system.Sites are expected to create a full initial assessment in the onlin
7、e tool and then continue to work in the tool each quarter to the degree necessary to sustain continuous improvement.Machine GuardingThe use of properly installed and operating guards on machines in all areas of shops,labs,and production is a critical part of protecting our employees from injury when
8、 operating machines.The six-sided concept of protection is thinking about placing the machine in a box of protection from all sidesErgonomicsThe science and application of fitting the work to the worker.The TE Ergo program began in FY09 with training and tools in multiple languages for site teams.Al
9、l sites are required to maintain an active ergo program chartered to identify and reduce ergo risks in the workplace.The Ergonomic Job Measurement System(EJMS)risk assessment tool is used to evaluate ergonomic risk.BBS Behavioral Based SafetyBehavioral Based Safety was introduced across TE in FY11 t
10、o help employees conduct safety behavior observations.This long-term initiative ensures employee engagement in the safety program through peer-to-peer conversation and feedback.Selected employees are taught how to observe safe and at-risk behavior and how to engage employees in constructive conversa
11、tion intended to support or modify behavior as necessary.Each site should be in a regular rhythm of observations.AgendaCore Safety ProgramsS.A.F.EErgonomicsMachine GuardingBehavioral Based SafetyStar Level Requirements SafetyStar Level OverviewStar Level 1 Getting started:Building Safety awareness a
12、nd plansStar Level 2 System Initiation:Sites are beginning to work on core TE Safety programsStar Level 3 Development:Sites are showing improvements on safetyStar Level 4Maturity:Safety programs become consistent,repeatable,and sustainable.Star Level 5 Excellence:a culture of safety is evident and s
13、coring in S.A.F.E has reached the highest percentile.Star Level Requirements SafetySL1 Getting StartedWhat to look for:A schedule of safety programs and dates when the site will implement each program.Evidence that the site has implemented each program on schedule.Documentation that BU EHS managemen
14、t agrees with the schedule and has approved any extension to implementation dates if necessary.What to look for:Focus on production,warehouse,lab,and other direct support jobs;not necessarily office workers.The TE EHS Onboarding Module alone is not adequate to meet this requirement;training may be o
15、nline or classroom,but must also include site-specific safety orientation.Employees include;fulltime,part time,and temporary This requirement is intended for new hires on or after October 1,2014SL1 Getting StartedWhat to look for:Ask the site safety leader to access the EHS database and show you req
16、uested data Check to see that hours are entered each month;Recordable injuries,if any,are entered;Site contact information for the safety person and plant manager is entered at a minimum and is currentSL1 Getting StartedWhat to look for:Skilled-Degreed in one or more aspects of EHS.A minimum of 4 ye
17、ars of experience may substitute for the degree and experience requirements with the approval of site BU EHS management.Experienced-Minimum of 2-years prior work experience in one or more aspects of EHS.SL1 Getting StartedWhat to look for:Check written accident and injury reports Information on what
18、 constitutes a“recordable injury”can be found on the TE EHS website.SL2 System InitiationWhat to look for:The site has implemented the requirements of the TE Ergo Program.Program materials can be found on the TE EHS website.An ergo team has been established and the members have been trained(attendan
19、ce sheets)The TE EJMS(or an equivalent)is used as the ergo risk assessment tool Documentation that ergo projects are prioritized and tracked to completion or on schedule as set by the site.The total risk score from all EJMS has been determined and represents the site baseline.The baseline ergonomic
20、risk score is set in the initial year of the program and then reset at the end of each following year.Records of each years baseline should be maintained for trending progress year-over-year.SL2 System InitiationWhat to look for:Review the requirements for machine guarding and risk assessment in the
21、 TE Machine Guarding Standard and the TE Milling Machine and Surface Grinder Safety Standard found on the TE EHS website.Documentation that the site has begun,but perhaps not finished,risk assessments of all machines where moving machine parts can be accessed by workers and should be guarded.Any doc
22、umented method of risk assessment is acceptable A corrective action plan that tracks machine guarding projects to completionSL2 System InitiationWhat to look for:Ask the site safety contact to access the online S.A.F.E.application for your evaluation Any complete assessment(all 18 elements of the Sa
23、fety Management Module)will meet this requirement.On day 1 of FY16 the site must also have completed one full assessment of the Critical Module(4 elements.)All elements must have an element owner assigned.No one person can own more than 5 elements in the Safety Management Module and 1 element in the
24、 Critical Module.Action plans are built into the S.A.F.E.application.Look to see they are being used as a corrective action tracking method.SL2 System InitiationWhat to look for:Sites are not required to enter first-aid cases and near-hit incidents into the EHS database,only recordable injuries are
25、required.However,sites may use the EHS database to track all first-aid and near-hit events along with all recordables if they choose.Look for some documented method for tracking all first-aid,near hits,and recordables;and some documented means of prioritizing actions to address trends discovered in
26、the data.SL3 DevelopmentWhat to look for:Sites may use their own training materials if approved by BU EHS management.The“production workforce”is essentially all non-office personnel engaged in manufacturing and support functions where risk of injury due to hazards in the workplace are likely to exis
27、t.The“10%trained observers”and“20%observed each month”are guidelines.BU management may approve their own targets for each assuming they are equally effective or more so.Look for separate training materials and attendance sheets for both trained observers and all other production employees.Review che
28、cklists to ensure they are heavily weighted toward actions(lifting,bending,tool use,etc.)and not conditions(housekeeping,machine guarding,etc.)SL3 DevelopmentWhat to look for:Evidence that the site is maintaining an active ergonomics team and program(meeting minutes;updated assessments;current proje
29、cts;etc.)Evidence that new and transferred machines,processes,work cells have been risk assessed for ergonomics prior to allowing employees to work in full production.Sites in year 2 of the TE Ergonomics Program must target and reach a 20%reduction in overall ergo risk by the end of year 2 from the
30、baseline established in year 1.SL3 DevelopmentWhat to look for:Documentation that the site is tracking and reviewing machine guarding risk assessments and projects.Walk the plant floor and machine shop to look for evidence that machines are effectively guarded.Select a representative sample of machi
31、nes for visible review of guarding to see if it appears to match requirements of the requisite standards.A detailed inspection/audit of machine guarding effectiveness is not expected of the TEOA assessor in this review but is as an ongoing requirement of site and BU management.SL3 DevelopmentWhat to
32、 look for:Access the S.A.F.E.application with the assistance of the site safety person.Look for evidence that the site has worked in S.A.F.E each prior quarter.Continuously changing scores,quarter-to-quarter,will meet this requirement.Scores that dont change are evidence of inactivity.Access S.A.F.E
33、.or Cognos reports to confirm that the current S.A.F.E.score is at or above 80 The“current S.A.F.E.score”consists of only the Management Systems Module through FY15.Beginning in FY16 it will also include the combined Management Systems and Critical Modules score.SL3 DevelopmentWhat to look for:BBS o
34、bservers receive a one-on-one assessment of their observations skills by another BBS observer;trainer;BU leader;or through the Aon BBS support program at least once each year.Assessments are not required in writing.Any evidence that this is an active site program is sufficient including interviewing
35、 some observers to see when they last participated in an assessment.Data on safe behaviors and at-risk(unsafe behaviors)as described in the requirement.Data should not be traceable back to any observed individual.Review BBS checklists to ensure they are customized to departments and standard work,no
36、t generalized for use anywhere in the plant.SL4 MaturityWhat to look for:Evidence that the site is maintaining an active ergonomics team and program(meeting minutes;updated assessments;current projects;etc.)Calculating%High Risk=Total all high risk scores by line item on each EJMS Total of all EJMS
37、scores(current baseline or latest totals)Any documentation that represents a corrective action plan to reduce the balance of high risk to zero.The corrective action plan must have owners assigned and estimated completion dates.SL4 MaturityWhat to look for:Documentation that there is a quarterly revi
38、ew of S.A.F.E.with the site manager.Access S.A.F.E.or Cognos reports to confirm that the current S.A.F.E.score is at or above 80.The“current S.A.F.E.score”consists of only the Management Systems Module through FY15.Beginning in FY16 it will also include the combined Management Systems and Critical M
39、odules score.SL4 MaturityWhat to look for:Employee engagement in the safety program should include a variety of options and opportunities for any employee to participate;BBS observer,safety project team member,safety promotion committee,safety committee,ergo team member,S.A.F.E.element owner or acti
40、ve participant,etc.Evidence that opportunities are varied and numerous Evidence that the site tracks overall participation rates and reports internally and to the BU as a KPI.Participation in mandatory programs or training does not qualify.SL5 ExcellenceWhat to look for:The first part of this requir
41、ement description is aspirational and is not intended to be measured by the TEOA assessor.Using data collected on safe and at-risk behaviors the site can calculate and maintain a current%safe score(total number of safe observations during the last 30 90 days /total number of observations for the sam
42、e period.)Any data points 90 days is not current.The site may determine which period they would prefer to track;30,60,or 90 daysSL5 ExcellenceWhat to look for:Evidence that the site is maintaining an active ergonomics team and program(meeting minutes;updated assessments;current projects;etc.)Use the
43、 same calculation method as explained for SL4-2 in determining all medium ergonomic risk.SL5 ExcellenceWhat to look for:Same documentation as described in SL4-3 Current S.A.F.E.score is at or above 90SL5 ExcellenceSummarySafety is a core valueIt is everyones responsibility to foster a culture of saf
44、ety The goal is zero incidents.12/24/2022page 35/New TEOA Safety ToolScenarios for SL Advancementor,demotion1.Today,November 6-2013,Bldg 123 is a SL3 siteAchieved SL3 under existing 14 tools(w/o new safety tool)On Oct 1,2014(FY15 day 1)site has not achieved SL3 on safety tool.How many months from Da
45、y 1 for grace period?Answer:0,There is no grace period after Day 1 of FY1512/24/2022page 36/New TEOA Safety ToolScenarios for SL Advancementor,demotion2.Today,November 6-2013,Bldg 456 is a SL3 siteThey achieve SL4 on tools(14 tools w/o new safety tool)and metrics on April 1,2014.Do they advance to S
46、L4 on April 1?YesIf,yes,do they need to achieve SL4 on the safety tool by the first day of FY15?Answer:Yes,there is no grace period after Day 1 of FY15.12/24/2022page 37/New TEOA Safety ToolScenarios for SL Advancementor,demotion3.On Day 1 of FY15,Bldg 789 achieves SL4 on all tools and metrics except for the new safety tool.Does the site advance from SL3 to SL4 on Day 1?No.Could they advance on Day 1 if they offer a“get well”plan?No.