PROBLEM STATEMENT:

MAN MACHINE MATERIALS MEASUREMENT ENVIRONMENT

WHY #1 WHY #2 WHY #3 WHY #4

PEER TO PEER - Measurement

No easy access to an analysis of data

The documentation process is too new

Was available, but taken off due to LiveLink constraints

FORKLIFTS - Machine

Operators were sharing badges for InfoLink access = a huge safety concern

Data in Infolink was scrambled due to Fort Worth integration

System was outdated due to administration gaps

FORKLIFTS - Measurement

No SOP for power industrial vehicles per 12 Basics Requirement

The lack of SOP had not been identified before

CONTRACTOR VIDEO/ COMMERCIALS - Measurement

Lack of resources and skill set to develop and produce video training tools

Skill sets and time are unavailable

MSDSonline - Measurement

Outdated inventory list

Change in regulations & needed to streamline processes to standardize throughout NORAM

No dedicated resource methodology

Safety Internship (Utilizing 5 Why Format)

1. Created an analysis file that links to the data file for real time

1. Ensured training records were up to date and added current badge numbers. 2. Compared

training records with Infolink. 3. Drafted mass communication concerning proper access to

Operators

IN SOME SITUATIONS (NOT ALL), YOU COULD GENERATE A 5-WHY FOR EACH OF THE FACTORS ABOVE

Gap of Safety Resources

Referenced OSHA etool and used the template to draft plant specific procedures

Contracted a local videographer to produce both contractor and Minster Masters commercials with

provided resources

1. Received training and implemented website. 2. Next phase, an ongoing administrator needs to be

identified

POTENTIAL CAUSESPOSSIBLE COUNTERMEASURE(S)

REMEMBER TO

CONSIDER

Peer to Peer Updating• Updated Peer to Peer database weekly • Created an Excel sheet that automatically updates,

directly from Livelink, visual representations of the data• Created a Mid-Point review presentation

• Analyzed the data to gauge progress• Posed suggestions for new card formats

Number of Conversations Graph

Observed Behavior Analysis

Power Industrial Vehicles• Updated the Forklift Training Excel sheet

• Added new employees• Moved employees no longer with the company to bottom of sheet• Added new trainings as they were completed

• Cleaned up the InfoLink system • Inputted most current badge numbers• Ensured employees had the appropriate access• Drafted announcement to Operators concerning access

• Helped assemble a forklift training SOP (12 Basics) • Worked with operators to replace photos in a pre-made OSHA

template• Updated descriptions to fit Minster’s particular power industrial vehicles• Document still in draft form

Forklift Certification Excel Sheet

Screenshot of Forklift SOP

Minster Masters• Participated in an event meeting• Environmental and Peer to Peer subject matters

• Wrote 2 minute commercial scripts for both subjects• Assisted in writing game questions

• Recruited a videographer to produce the 4 commercials needed

• Project still underway

Contractor Video • Used Thumbtack to find a videographer to create a new

video• Took multiple offers and narrowed it down to one company

• Created a Minster specific script for the video• Based off of existing script, pamphlet, and Grab & Go binder

• Project still underway

MSDSonline • Took several chemical inventories from different zones and

compiled them into one document• Went from over 1,400 active chemicals to 350• 75% reduction in chemical inventory listing • Created a new Excel sheet to reflect updates

• Converted Active Chemicals Excel sheet to MSDSonline• Added a Risk Assessment element after 12 Basics Audit• Worked with MSDSonline to try to make site more user-friendly

• Created a training to acquaint workforce with the new system• Presented four train the trainer sessions to Managers, Supervisors, and Cell

Owners• Ongoing to roll to workforce

• Revisions for Chemical Control SOPs (004, 055) & Chemical Approval sheet (QAR 032) to reflect both GHS and MSDSonline

• Conducted floor secondary container label research to comply with new GHS standards

Active Chemical Inventory - Before

Chemical Inventory - After

MSDSonline – Viewer Homepage

MSDSonline – User Friendly Examples

WISE & 12 Basics Audit Week• Assisted with the preparation for the week

• Updated the WISE binder• Put together packets and safety equipment for visitors• Helped check the plant to ensure it was up to standards

• Updated Grab & Go binders: First Aid and Hazmat information• Updated Emergency Evacuation Maps throughout the plant

• Participated in the Chemical & Emergency Procedure Audits• Answered Auditor questions• Provided needed documentation

• Sat in on the closing meeting and workshop

Conclusion• Learned about all parts of the plant working in Safety• Improved Excel abilities (Peer to Peer, MSDSonline)• Gained skills in project work (MSDSonline, Contractor video,

Minster Masters)• Coordinating with others at all levels of Organization

• hourly, supervisors, managers, vendors, and auditors• Maintaining a timeline of work • Presentation skills

• Audit Experience• Professionalism