Author: Megan Raines, CSP, Corporate Safety Manager
In the manufacturing business, “lean” is a frequent buzzword. Lean principles are used to improve productivity, reduce cost, improve quality, organize work areas, and standardize processes. But how often do you hear of safety improvements in the list of business priorities that can be touched by lean? As lean concepts continue to become more and more engrained in corporate culture, hopefully you will hear “safety” used in conjunction with lean on a more frequent basis. After all, processes cannot be considered lean without also being safe.
So how can safety be improved by implementing lean? Actually, the two can work hand-in-hand. Recent initiatives at Comau provide excellent examples of how lean initiatives can also improve safety. Comau has embraced a lean manufacturing philosophy which emphasizes continuous improvement. While we are known for our excellent safety record, we also strive toward continuous improvement in our safety performance as well. I have been working with the teams who are implementing our lean manufacturing initiatives to create synergies between lean and safe. For example:
· Lean “5S” initiatives: 5S implementation results in improved cleanliness and housekeeping, which can reduce clutter and thereby reduce the potential for several types of injuries. Also, 5S emphasizes standard processes; safety requirements can be integrated into these processes. In fact, 5S and safety are so closely linked that sometimes safety is considered a 6th “S”. (And yes, I can sometimes be seen with a broom or dustrag helping the lean teams “shine” the areas!)
· Improved process flow: Improving process flow normally results in less process steps and less travel distance. These changes can improve ergonomics and result in less strain on the body.
· Workplace organization: Not only does this result in better housekeeping (see above), but by placing frequently used items within easy reach it can also improve ergonomics and result in less strain on the body.
· “Kaizen” workshops: These workshops are designed to identify forms of waste and address them to streamline processes. In addition to the benefits listed above, they are also an excellent opportunity to identify any tools or equipment which will help to make the workplace safer.
Comau is becoming more widely known for our integration of lean and safety. In fact, I am working on an article about this integration (and how to get employees to want to participate in safety improvements), and I hope it’ll be featured in a professional publication soon.