Table Of ContentLean Methods & Implementation H
A
F
E
Y
Lean Safety Gemba Walks
Lean Safet y
A Methodology for Workforce Engagement and Culture Change
“Employee safety is the ultimate responsibility of any leader. Lean provides
the ultimate set of guiding principles for any leader. Hafey, in his second book
on the combined topic, shows us how leaders can use safety to deploy Lean Gemba Walks
principles on the Gemba to supercharge the performance of any organization”
—Dan McDonnell, Vice President, Integrated Supply Chain, Ingersoll Rand
“The idea of recognizing safety risks as opportunities for Lean improvement
L
is unique. By making a work activity safer we also make the work more
E
productive.” A A Methodology for Workforce
N
—Mikelis (Mike) Abuls, Executive Vice President & COO, CG Schmidt, Inc.
S
“After decades of grappling with variability in Lean implementation results, A Engagement and Culture Change
along comes Lean Safety Gemba Walks and ties all the loose ends F
E
together into a coherent, practical, and very powerful approach to the
T
engagement of the hearts and minds of those employees who traditionally Y
suffer the most injuries, the very same people who we want to ‘transform’
G
into efficient assets.” E
M
—Wayne Burton, Manufacturing Manager, Bricks East Coast, Boral
B
Clay & Concrete
A
W
Lean Safety Gemba Walks: A Methodology for Workforce Engagement
A
and Culture Change is a follow-up to the author’s bestselling book, Lean
L
Safety, published in 2010. It is a natural progression from the philosophical K
overview provided by Lean Safety to the reality of the application of those S
principles in facilities around the world.
This book presents a collection of Lean Safety Gemba Walk case studies
that are based on the author’s experiences over the last four years. As the
stories unfold, readers are transported on a journey of discovery through
the Gemba and begin to see safety differently—just as those who physically
participated.
K24162
ISBN: 978-1-4822-5898-1 Robert B. Hafey
90000
9 781482 258981
Lean Safety
Gemba Walks
Lean Safety
Gemba Walks
Robert B. Hafey
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
A PRODUCTIV ITY PRESS BOOK
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2015 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20140711
International Standard Book Number-13: 978-1-4822-5899-8 (eBook - PDF)
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been
made to publish reliable data and information, but the author and publisher cannot assume responsibility for the valid-
ity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright
holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this
form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may
rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or uti-
lized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopy-
ing, microfilming, and recording, or in any information storage or retrieval system, without written permission from the
publishers.
For permission to photocopy or use material electronically from this work, please access www.copyright.com (http://
www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923,
978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For
organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for
identification and explanation without intent to infringe.
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
Dedication
To those who by working with their hands provided me the material
and inspiration to write this book. May the material in this book
help keep them and all who work with their hands safe.
Contents
Acknowledgments ............................................................................ ix
Introduction ..................................................................................... xi
1 The Common Objective—Impact the Culture by Building Trust ...1
2 Compliance-Based Safety—Not Good Enough .............................7
3 Behavior-Based Safety versus Lean Safety ................................15
4 Living Injury-Free Every Day versus Living Painkiller-Free
Every Day ...................................................................................25
5 A Safety Walk versus a Safety Gemba Walk ..............................33
Product Flow .............................................................................................40
Material Handling Methods ......................................................................40
Storage Containers ....................................................................................41
Plant Layout ...............................................................................................42
Block Diagramming ..........................................................................42
Relationship Diagramming ................................................................42
Rules for Engagement ........................................................................43
CASE STUDIES
Case Study 1 Metal Fabrication Operation, Ohio....................................49
Case Study 2 Electrical Cabinet Assembly Operation, Indiana ................55
Case Study 3 Distribution Center, Nevada ..............................................59
Case Study 4 Transformer Manufacturer: Power Partners, Inc.,
Athens, Georgia .................................................................................65
Case Study 5 Industrial Distributor, Pennsylvania ...................................71
Case Study 6 Mining and Metals: Metinvest, Donetsk, Ukraine ..............75
vii
viii ◾ Contents
Case Study 7 Food Plant, Australia .........................................................81
Case Study 8 Chemical Plant: Nufarm Limited, Victoria, Australia ..........85
Lean Safety Workshop/Kaizen Event Feedback .......................................88
Impressions—What impressed you the most? ..................................88
What can you take away and apply in your workplace? .................88
Learnings—Personal learnings for me .............................................89
Case Study 9 Recreational Vehicle Plant, United States ..........................91
Case Study 10 Food Plant, United States .................................................95
Case Study 11 Sheet Metal Fabrication Plant: KSO Metalfab Inc.,
Streamwood, Illinois ........................................................................101
Case Study 12 Medical Device Component Plant: Specialty Silicone
Fabricators, Paso Robles, California .................................................109
Case Study 13 Coiled Metal Processing Plant, Australia ........................113
Case Study 14 Medical Products Plant, Australia ..................................119
Case Study 15 Heavy Machined Products Plant, United States .............123
Case Study 16 Custom Field Service Vehicle Plant: Stellar Industries,
Inc., Garner, Iowa ............................................................................127
Case Study 17 Machining and Assembly Operation, Canada ................131
Case Study 18 Sheet Metal Products Plant, Canada ..............................135
Case Study 19 Beverage Can Operation, United Kingdom ....................139
Case Study 20 Process Production Operation, Australia .......................143
Conclusion ......................................................................................147
About the Author ............................................................................159
