Acknowledgments | p. xi |
Introduction | p. xiii |
Why Focus on Safety? | p. 1 |
Demonstrate That Safety Really Is First | p. 1 |
Quick Guide: Lean Focused Approach to Safety Management | p. 7 |
Endnotes | p. 8 |
Change the Culture | p. 9 |
A Common Goal of Both Lean Philosophy and Safety Programs | p. 9 |
Quick Guide: Change the Culture | p. 13 |
Leadership's Role | p. 15 |
Focus Everyone on the Process | p. 15 |
Quick Guide: Leadership's Role | p. 24 |
Lean Tools for Safety | p. 25 |
You Can Continuously Cope or You Can Continuously Improve-The Choice Is Yours | p. 25 |
Lean Tool 5S: A Structured Method of Workplace Organization | p. 27 |
Sort | p. 28 |
Set in Order | p. 28 |
Shine | p. 29 |
Standardize | p. 30 |
Sustain | p. 31 |
Disciplined Approach Necessary to Maintain Safety in the Workplace | p. 32 |
Lean Tool: Visual Factory | p. 34 |
Signage | p. 34 |
Charts | p. 36 |
Signaling Systems | p. 36 |
Process Mapping | p. 37 |
Lean Tool: Training | p. 37 |
Lean Tool: Poka-Yoke (Failsafe) | p. 39 |
Lean Tool: Benchmarking | p. 40 |
Lean Tool: Continuous Flow/Cycle Time Gains | p. 41 |
Lean Tool: Standard Work | p. 43 |
Lean Tool: Problem Solving | p. 45 |
Lean Tool: Metrics | p. 48 |
Lean Tool: Teams | p. 49 |
Quick Guide: Lean Tools for Safety | p. 51 |
Endnotes | p. 52 |
Advanced Lean Tools for Safety | p. 53 |
Facilitated Leadership: Changing How People Think | p. 53 |
Lean Tool: A3 Problem Solving | p. 53 |
State the Agreed Upon Problem or Need | p. 54 |
Draw the Current State Map or State the Current Condition | p. 54 |
Problem Solving-Use Ask "Why" Five Times Technique to Get to Root Causes | p. 54 |
The Future State-Draw a Map or Describe How You Would Like It to Be | p. 57 |
Implementation Plan | p. 57 |
Audit Expected Results against Actual Results | p. 57 |
Lean Tool: Kaizen Blitz | p. 58 |
Planning the Kaizen Event | p. 61 |
Facilitating the Kaizen Blitz | p. 68 |
Kaizen Team Presentation | p. 78 |
Kaizen Event Follow-Up Meeting | p. 80 |
Quick Guide: Advanced Lean Tools for Safety | p. 91 |
Endnote | p. 91 |
Safety Program Leadership | p. 93 |
It Doesn't Have to Be a Manager | p. 93 |
Team Leader | p. 95 |
Management Facilitator | p. 95 |
Accident Investigation Facilitator | p. 95 |
Recorder Keeper | p. 96 |
Subteam Leaders | p. 96 |
Human Resources (HR) Facilitator | p. 99 |
Safety Walk Co-Coordinator | p. 99 |
OSHA Knowledge Expert | p. 99 |
Training Coordinator | p. 100 |
Quick Guide: Safety Program Leadership | p. 102 |
Endnote | p. 103 |
Incident/Accident Investigation | p. 105 |
Getting to Root Causes and Lasting Solutions | p. 105 |
Focus on Process, Not People | p. 106 |
Getting to Root Cause and Corrective Actions | p. 108 |
Quick Guide: Lean Approach to Incident and Accident Investigations | p. 112 |
Promoting Safety | p. 113 |
Engaging Employees to Build Safety Awareness | p. 113 |
Flash Meetings | p. 114 |
Benchmarking (A Standard against Which Something Can Be Measured or Assessed) | p. 114 |
Safety Improvement Programs | p. 116 |
Safety Observation Program | p. 117 |
Job Safety Analysis | p. 119 |
Safety Kaizen Blitz Events | p. 119 |
Quick Guide: Lean Approach to Internal Safety Promotion | p. 120 |
Roadmap to World-Class Safety | p. 121 |
Pulling the Pieces Together to Build or Rebuild a Safety Program | p. 121 |
Safety Program Leadership | p. 122 |
Lean Approach to Safety Program Leadership | p. 122 |
Safety Team | p. 122 |
Lean Approach to a Safety Team | p. 123 |
Other Team Building Opportunities | p. 124 |
Recordkeeping | p. 126 |
Lean Approach to Recordkeeping | p. 126 |
Safety Program Outline Documents | p. 127 |
Safety Education | p. 127 |
Lean Approach to Safety Education | p. 128 |
Safety Program Activity Management | p. 129 |
Lean Approach to Safety Program Activity Management | p. 129 |
Safety Rule Definition | p. 131 |
Lean Approach to Safety Rule Definition | p. 131 |
Safety Communications | p. 132 |
Lean-Influenced Safety Communications | p. 132 |
Quick Guide: Roadmap to World-Class Safety | p. 133 |
Safety Standard Work | p. 135 |
Foundation of Continuous Improvement | p. 135 |
Quick Guide: Standard Work for Managers | p. 138 |
Endnote | p. 138 |
Safety Metrics | p. 139 |
What You Measure Makes a Difference | p. 139 |
Lean Approach to Safety Metrics | p. 140 |
Quick Guide: Metrics | p. 142 |
Conclusion | p. 145 |
Glossary | p. 147 |
Index | p. 153 |
About the Author | p. 163 |
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