Wayne Punch Director Emeritus, Safety / Security Milliken & Company Millikens Safety Processes.

Wayne PunchDirector Emeritus, Safety / Security

Milliken & Company

Milliken’s Safety Processes

© Sylvan Chemical Co., Inc. 2010. All Rights Reserved.2

Associate Engagement


A Customized System ofcultural safety consciousness that

Milliken Safety Way System Milliken Safety Way System

engages entire workforce,produces proactive focus, andutilizes continuous improvement

for an injury-free workplace.


The safety and health of all its people is of primary importance to Milliken & Company. Milliken will devote resources to train its people to perform their jobs safely, to insure equipment can be operated in a safe manner, to eliminate workplace hazards and to comply with applicable safety and health laws and regulations. Milliken believes that all injuries are preventable, all health risks are controllable and that management is accountable.

ChairmanMilliken & Company

Milliken & Company Safety PolicyMilliken & Company Safety Policy


PREDICTIVE

PREVENTIVE

REACTIVE1985 Transition to Associate-Led Teams

1990 Leadership Commitment , Involvement, Support

1992 Partnered with OSHA VPP Star – Associate Empowerment & Compliance

1996 Milliken Performance System

2000 AppliedContinuous Improvement Methodologies

2005 Focused onHazard/Risk Reduction

TODAYEquipmentConditionsBehaviors

Continuous Improvement

Evolution of the Milliken Safety ProcessEvolution of the Milliken Safety Process


Total Recordable Incidence RatesTotal Recordable Incidence Rates

An Industry-Wide Comparison


Driven From the Top Down

Safety Operations Strategy Developed at Corporate Level

Generic Initiatives are Directed to Sites

Ownership and Emphasis has Variation

Implementation has Variation

Lack of Individual andGroup Commitment

Limited Results

Management Control Impedes Involvement and Interaction

Common Safety PracticeCommon Safety Practice

EmployeeDisconnect

ConsequenceDriven

Process


Leadership Development and Support

Steering Team Development

Sub-Committee Development

Individual Development

Knowledge & Awareness


A New Safety Strategy A New Safety Strategy

Empl

oyee

Eng

agem

ent

Prev

entiv

e / P

redi

ctiv

e D

riven

Pro

cess


Education

Resources

Empowerment &Commitment

Positive Process

Mission / Vision

Key Components of the Safety ProcessKey Components of the Safety Process


Exercise

No Smoking

Stress

Diet

Education

Resources


Positive Process

Mission / Vision

Peer To Peer

Wellness

First Aid/C.P.R.

Benchmark

Health Risk

Protective Equipment

Procedures

E.R.T.

Methods

Benchmark

First Aid/C.P.R.

Technical

Social



Education

Resources


Positive Process

Mission / Vision

Involvement

Time

Community

Space

Information

Teams

Managers

Video

Publications

Hospital

Highway Patrol

DHEC

Wildlife

Fire Dept.

Co. Extension

Budget

ToolsMaterial

Organizational Structure



Education

Resources


Positive Process

Mission / Vision

Strategy

GoalsProcess

Results

POE

Recognition

Audits

Surveys

Feedback

Whole Person

Expectations

Interaction

Process

Education

ResourcePlanning

Measurement

PurposeContinuous

Improvement



Education

Resources


Positive Process

Mission / Vision

Teamwork

Authority

Responsibility

Accountability

Rules

Counsel

Policy

Schedule

Stop Unsafe Acts or Conditions

Commitment

Consistency



Education

Resources


Positive Process

Mission / Vision

Recognition

Freedom to Try

Trust

Fun/Interesting

Individual

Team

Plant

Structure Teams



Standardized Daily Management System

Models, Common Language

Standardized Problem-Solving Approach

Standardized Education Process

Consistent Measurement Process

Empowered and Engaged Associates

The Journey to World Class PerformanceThe Journey to World Class Performance


1. Give employees the tools they need to lead the safety process (education, time, resources, etc).

2. Leadership must serve as sponsors - make yourself available!

3. Communicate well with the team.Do not shoot the messenger.

4. Support their ideas. Everyone deserves to be heard!

5. Understand that SAFETY should be integrated into the organization’s daily functions.

How Do You Empower People ?How Do You Empower People ?


To calculate % employee involvement, at least one of the following criteria must be met:

• serve as a Steering Committee member• serve as a Sub-Committee member• perform diagnosis / audits (equipment & conditions)• train / educate other employees in safety• serve as a safety team leader• perform observations (behavior)• be involved in a hazard reduction process

How Do You Measure Involvement?How Do You Measure Involvement?


What do you really measure?

Does it have the ability to drive your process towards zero incidents?

How Do You Measure Involvement?How Do You Measure Involvement?


Safety Way Process: How It WorksSafety Way Process: How It Works

Key Components of SystemCommitment

Education

Audits

Measures

Activities

Analysis

Zero Thinking

Organizational Alignment

Change Readiness

Value Driven

Corporate Guidelines

Site Assessments

Strategic Planning

Multi-level Communication



Commitment

Education

Audits

Measures

Activities

Analysis

Gap Analysis

Verify the Tasks

Leading and Lagging Indicators

Scoreboards

Business Case

Surveys

Observation

Committee Reviews

Key Components of System



Commitment

Education

Audits

Measures

Activities

Analysis

Technical & Soft Skills

Build the Process

Incorporate Compliance and Standards




Commitment

Education

Audits

Measures

Activities

Analysis

Awareness

Establish Motivational Methods

Project Management

Organize and Train




Commitment

Education

Audits

Measures

Activities

Analysis

Conditions & Equipment

Behavior Observations

Causation Tools

Behavioral Development




Commitment

Education

Audits

Measures

Activities

Analysis

Incident Profiles

Job Safety Analysis

Risk Assessments

Correctional Methods



Roles and Responsibilities of a Safety ProcessRoles and Responsibilities of a Safety Process

LeadershipLeadership

ManagementManagement

EmployeesEmployees

Establish Safety as a Value, Demonstrate Commitment to the

Journey

ROLE in the Safety Process RESPONSIBILITY of each Role

Provide the ‘Tools to Improve’, Sustain the Gains

Empower and Engage


Safety becomes an integral part ofCompany’s Operational Excellence Strategy

Safety as a Corporate ‘Value’ SystemSafety as a Corporate ‘Value’ System


What is the

CHANGEthat must occur?


To Achieve an injury-free workplace we must change the practices…

Organizationallyand Individually

This is Culture Change

What has to Change:What has to Change:


Commitment at all Levels (Vision, Modeling, Time, Structure)

Measure and Review (Inputs & Outputs)

Communications (Recognition/Accountability)

Education (Leading Change, Subject Matter)

Audits & Analysis (Standardizing, Improvement)

Culture Change:Culture Change:

Organizational:


It IS about a CONTINUOUS IMPROVEMENT SYSTEM

that concurrently achieves

Organizational and IndividualCHANGE

in the uncompromising pursuit of zero.

Culture Change:Culture Change:


Questions?

Wayne Punch Director Emeritus, Safety / Security Milliken & Company Millikens Safety Processes.

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