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N. Guzel

Plant Nieuwegein

20-12-2019

SHE pillar Workshop

Problem description

What Problem/ Why is it a problem?

Aug

Volumereduction and costpressure

Issue

Problem Description

Project Description

  • For decades we use to have a two shift patron and no formal lunchbreak. (so called flying break, machines continue to run) Due to volumereduction and costpressure we have to reduce this for the majority of the plant to an extended dayshift and introduce fixed breaks in privat time.
  • There is one shift for the production team is from 6 a.m. to 3:30 p.m. Except for the Mixing department.
  • Mix 2 does not fit 1 shift, which means that 2 people have to work from 2 p.m. till 10 p.m.
  • This has an huge impact on emergency plan (not enough ERT member Etc) communication and also for start up and shut down continuous proces, introducing potential new hazards and risks.

Team

Team

Improvement Route

Improvement route

Project description

Define Project

  • In June 2019 started the Shift Patron change (pilot for 4 months).
  • From 2 shifts to 1 shift for the whole production team
  • Except for the mixer 2
  • The mixer needs to run 65 - 70 hours a week

Huge impact (new risks) for the mixer 2:

  • Communication
  • Emergency plan
  • Start up and Shut down of mix 2
  • Closing the plant

Project Goal

Reducing the risks with 30 % for the mixer 2 staff, who have to work alone in the evening

Project Goal

Collect Data (Plan)

Collect data, document, interview and analyze risky situations to the operation, Risk Assessment, MOC

Sept

MOC's

MOC

Analyze BSD's

BSD's

Reports (incidents)

Reports

Interviewing employee mixer 2

Interview

Risk Assessment

Planning

Restore machine (do)

Restore the machine and the factory standard

Okt

Starting up and shutting down

Starting up Shutting down

Changing Procedure

  • Procedure
  • Work instructions
  • SOP
  • OPL's

Procedure

Implement

Implementation is the process of executing a procedure so that a concept becomes a reality

Several sessions of evaluations with the team of the mixer

Implement

Restore behavioral (do)

Restore behavioral standard and Training

Nov

First Aid trainings

The whole Mixer team had two days First Aid training.

Two members of the mixing team are also in the emergency responds team (ERT)

Training

Communication

At least 3 employee in the evening

Because of the Mobile phone policy, no phone where allowed

Communu-cation

Closing round

Check en Act

Examen the residual risk and reduce them when required

Goal Achieved?

Planning closed

Continuous Improvement

Dec

Observation

Observation the mixer team in the evening

Workplace inspection

Interviewing the team

Checking the BSD's and safety reports

Observation

Residual risk

Risk residual

Goals achieved

Goals?

Target: Reducing the risks with 30%

Total risk rating -> 34

Total residual risk rating -> 18

Risk reducing 52 %

Goals is achieved!

Planning closed

Actions closed

Feedback and Shared

The result are shared with work-council, unions and shop floor

Also feedback to employees

Feedback and Sharing

Continues improvement

Continuous improvement

Continues improvement by:

  • Observations
  • Workplace inspections
  • Audits
  • BSDs
  • Safety reports
  • Toolbox meetings
  • Team evaluations
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