Successful Safety Evolution

1
Successful Safety Evolution

• Brian Zoeller, MS, CSP
• Vice President of Safety and Security
• Neenah Enterprises Inc.

2
History

• Neenah Foundry is a Division of Neenah
  Enterprises Inc.
• Established in1872
• 900 Employees
• Union Facility
• Municipal and Industrial Castings
• Municipal
• Manholes, Grating and Decorative castings
• Industrial
• Trucking, Agriculture, Construction

3
Safety Program History

• Simple Reactive Safety Culture
• Limited Staffing
• 1 Safety Professional
• Plant and Corporate responsibilities
• 2 Nurses
• 12 hour coverage
• Limited upper management support
• Safety program was secondary to plant operations
  and overall organizational strategy

4
Historic Safety Results
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New Corporate Commitment

• New management team started to be established in
  early 2011
• Understood the need for a corporate safety
  process
• Decrease injuries
• Engage workforce
• Improve facilities
• Decrease workers compensation cost
• Build safety into daily tasks
• Starting all meetings with safety
• Holding Safety Dept. monthly calls
• Recordable Safety AIR meetings
• KPIs (JSA, Safety Walk requirements)
• Adding committed resources

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Neenah Foundry Safety Team

• Safety Department
• Shawn Sexauer, Senior Safety Engineer
• Ryan Jakober, Safety Engineer
• Lisa Klaver, Safety Administrator
• Summer Interns
• Health Services
• Breanna Magley, RN - Supervisor
• Kim Birr, RN
• Ashley McKeown, RN
• Larry Stark, LPN

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Successful Safety Process Builders

• Creative
• Think outside the box
• Open minded approach
• Dont listen to the CAVE men
• Justified Work
• Run controlled experiments
• Understand basic business acumen
• Work as a team

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New Safety Process Approach

• Proactive
• Training
• New hire orientation (4 hours 2 days)
• OSHA training
• Job Safety Analysis (JSA) creation and training
• Training Within Industry (TWI)
• OSHA 10/30 hour courses
• Fox Valley training courses
• Safety Kaizen Events
• Work hardening
• Supervisor safety meetings
• Focus teams (Ergo, Safety, Wellness)
• Upgraded equipment
• PPE development
• Video creation

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New Safety Process Approach

• Reactive
• Incident investigation
• Safety blitz
• Intervention programs
• Safety hotline
• Monitoring
• RAIR/SAIR meetings
• Formal hygiene sampling
• Audits
• Safety walks
• Quarterly union plant walkthroughs

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Ergonomic Evolution

1. Utilized continuous improvement tools to track
   injuries (Pareto charts)
2. Created stretching programs for specific job
   tasks
3. Implemented Work Hardening program
4. Implement Department Stretching program
5. Utilized onsite Physical Therapy
6. Created training programs
7. Implemented ergonomic audits
8. Created ergonomic committee
9. Implementing POPE

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Ergonomic Stretching Program
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Ergonomics Work Hardening

• Work Hardening Program
• Work Hardening Objectives
• Decrease upper extremity soft tissue injuries in
  new hires
• Decrease new hire turnover
• Increase performance knowledge
• Program Basis
• Identified high and low impact tasks
• Implement stretching
• Eight week program that slowly increases the time
  and duration that the new employee is exposed to
  the job tasks
• Acclimate employees bodies to stresses of job
• Improve overall training program

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Ergonomic Training Program

• Training Included
• Definition of ergonomics
• Description of musculoskeletal injury (MSI)
• Tendonitis
• Carpal tunnel
• Shoulder strain/sprain
• Back strain
• Corrective actions
• Quick wins
• Capital projects

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Ergonomics POPE

• Post Offer Pre-Employment
• Screens new candidates for proper job fit
• Detailed assessments ensure
• Employee body is safe to perform the job
• Employee can handle the physical stresses of job
• Employee still wants to do the job
• Completed at NF Training Center
• Equipment designed and built to mimic job
  functions
• Conditions similar to working environment (noise,
  ambient air, PPE)

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Ergonomics Circle of Health
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Partnerships

• External
• Northeast Wisconsin Foundry Ergonomics
  Partnership (NEWFEP)
• OSHA
• Advanced Physical Therapy
• Blankenheim
• Internal
• Safety Focus Teams
• Ergonomics Committee
• Wellness Team
• Union Management Team

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AIC Safety Software

• Internet based software program that can manage
  and maintain your health and safety program
• Used for tracking
• Injury and illnesses
• JSAs
• Observations
• Training
• Near misses
• Fires
• Actively works with our insurance carrier to
  track claims
• Ability to assign corrective actions to
  individuals, which in turn increases
  accountability

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Safety Intervention

• Primary goal is to improve an employees safety
  behavior
• A tool to increase an employees safety awareness
  and improve their safe work practices
• Employees that meet the criteria for intervention
  are
• Injured but no safety violation and
• Injured more than three times in a rolling twelve
  month period

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Safety Blitz

• An investigative team that is designed to assist
  the supervisor when investigating a serious
  incident
• Assembled within 24 hours of the incident or
  sooner if needed
• Supervisor leads the team with the assistance of
  safety
• Union participation

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Training Center

• Area designed to conduct hands on training for
  employees
• Used to give new employees the exposure of
  working on the floor and handling castings in a
  neutral environment
• Confined space trainer
• Hands on ergonomic training
• Casting handling training
• Will be used for POPE testing

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Current Performance

• Currently at 1.5 million hours without a lost
  work day incident

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Safety Awards

• Wisconsin Safety Council
• Wisconsin Corporate Safety Award
• 2013
• American Foundry Society
• Metalcasting Safe Year Award 2013
• 2013 Millionaires Safety Award
• 3 million hours without incurring an occupational
  
• injury or illness that resulted in lost workday
  case

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Historical Trend
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Future State

• Neenah Foundry and NEI are continuing to change
  our safety cultures and improve our safety
  process.
• We are far from complete

25
Questions