Milliken’s Safety Processes Wayne Punch Director Emeritus, Safety / Security Milliken & Company Being a new team leader can be a little scary, especially at first, so this first lesson looks at how your role is changing from regular production associate to one with new responsibilities and what you need to remember as you transition into this role... (CLICK)

Associate Engagement

A Customized System of cultural safety consciousness that Milliken Safety Way System A Customized System of cultural safety consciousness that engages entire workforce, produces proactive focus, and utilizes continuous improvement for an injury-free workplace.

Milliken & Company Safety Policy The safety and health of all its people is of primary importance to Milliken & Company. Milliken will devote resources to train its people to perform their jobs safely, to insure equipment can be operated in a safe manner, to eliminate workplace hazards and to comply with applicable safety and health laws and regulations. Milliken believes that all injuries are preventable, all health risks are controllable and that management is accountable. Chairman Milliken & Company

Continuous Improvement Evolution of the Milliken Safety Process 1985 Transition to Associate-Led Teams REACTIVE 1990 Leadership Commitment , Involvement, Support 1992 Partnered with OSHA VPP Star – Associate Empowerment & Compliance PREVENTIVE 1996 Milliken Performance System 2000 Applied Continuous Improvement Methodologies PREDICTIVE 2005 Focused on Hazard/Risk Reduction Equipment Conditions Behaviors Continuous Improvement TODAY

An Industry-Wide Comparison Total Recordable Incidence Rates An Industry-Wide Comparison

Common Safety Practice Driven From the Top Down Safety Operations Strategy Developed at Corporate Level Generic Initiatives are Directed to Sites Ownership and Emphasis has Variation Implementation has Variation Management Control Impedes Involvement and Interaction Employee Disconnect Lack of Individual and Group Commitment Consequence Driven Process Limited Results

Continuous Improvement A New Safety Strategy Continuous Improvement Employee Engagement Preventive / Predictive Driven Process Knowledge & Awareness Individual Development Sub-Committee Development Steering Team Development Leadership Development and Support

Key Components of the Safety Process Education Resources Mission / Vision Empowerment & Commitment Positive Process

Key Components of the Safety Process Education Peer To Peer First Aid/C.P.R. Resources Exercise Wellness Social No Smoking Benchmark Stress Mission / Vision Health Risk Diet Empowerment & Commitment Protective Equipment Procedures Positive Process E.R.T. Technical Methods Benchmark First Aid/C.P.R.

Organizational Structure Key Components of the Safety Process Organizational Structure Education Teams Involvement Resources Managers Hospital Time Mission / Vision DHEC Highway Patrol Community Wildlife Empowerment & Commitment Fire Dept. Space Co. Extension Positive Process Video Information Publications Budget Material Tools

Continuous Improvement Key Components of the Safety Process Education Process Planning Resource Resources Strategy Recognition Education POE Mission / Vision Process Goals Results Empowerment & Commitment Audits Measurement Feedback Surveys Positive Process Whole Person Purpose Interaction Continuous Improvement Expectations

Stop Unsafe Acts or Conditions Key Components of the Safety Process Education Rules Teamwork Resources Policy Counsel Authority Mission / Vision Schedule Stop Unsafe Acts or Conditions Responsibility Empowerment & Commitment Accountability Positive Process Commitment Consistency

Key Components of the Safety Process Education Individual Recognition Team Resources Plant Freedom to Try Mission / Vision Trust Empowerment & Commitment Fun/Interesting Positive Process Structure Teams

The Journey to World Class Performance Standardized Daily Management System Models, Common Language Standardized Problem-Solving Approach Standardized Education Process Consistent Measurement Process Empowered and Engaged Associates

How Do You Empower People ? Give employees the tools they need to lead the safety process (education, time, resources, etc). Leadership must serve as sponsors - make yourself available! Communicate well with the team. Do not shoot the messenger. 4. Support their ideas. Everyone deserves to be heard! Understand that SAFETY should be integrated into the organization’s daily functions.

How Do You Measure Involvement? To calculate % employee involvement, at least one of the following criteria must be met: serve as a Steering Committee member serve as a Sub-Committee member perform diagnosis / audits (equipment & conditions) train / educate other employees in safety serve as a safety team leader perform observations (behavior) be involved in a hazard reduction process

What do you really measure? How Do You Measure Involvement? What do you really measure? Does it have the ability to drive your process towards zero incidents?

Key Components of System Safety Way Process: How It Works Key Components of System Commitment Zero Thinking Organizational Alignment Change Readiness Value Driven Corporate Guidelines Site Assessments Strategic Planning Multi-level Communication Measures Education Activities Audits Analysis

Key Components of System Safety Way Process: How It Works Key Components of System Commitment Gap Analysis Verify the Tasks Leading and Lagging Indicators Scoreboards Business Case Surveys Observation Committee Reviews Measures Education Activities Audits Analysis

Key Components of System Safety Way Process: How It Works Key Components of System Commitment Technical & Soft Skills Build the Process Incorporate Compliance and Standards Measures Education Activities Audits Analysis

Key Components of System Safety Way Process: How It Works Key Components of System Commitment Awareness Establish Motivational Methods Project Management Organize and Train Measures Education Activities Audits Analysis

Key Components of System Safety Way Process: How It Works Key Components of System Commitment Conditions & Equipment Behavior Observations Causation Tools Behavioral Development Measures Education Activities Audits Analysis

Key Components of System Safety Way Process: How It Works Key Components of System Commitment Incident Profiles Job Safety Analysis Risk Assessments Correctional Methods Measures Education Activities Audits Analysis

Roles and Responsibilities of a Safety Process ROLE in the Safety Process RESPONSIBILITY of each Role Establish Safety as a Value, Demonstrate Commitment to the Journey Leadership Provide the ‘Tools to Improve’, Sustain the Gains Management Employees Empower and Engage

Safety becomes an integral part of Safety as a Corporate ‘Value’ System Safety becomes an integral part of Company’s Operational Excellence Strategy

Continuous Improvement

What is the CHANGE that must occur?

Organizationally This is Culture Change What has to Change: To Achieve an injury-free workplace we must change the practices… Organizationally and Individually This is Culture Change

Culture Change: Organizational: Commitment at all Levels (Vision, Modeling, Time, Structure) Measure and Review (Inputs & Outputs) Communications (Recognition/Accountability) Education (Leading Change, Subject Matter) Audits & Analysis (Standardizing, Improvement)

Organizational and Individual CHANGE Culture Change: It IS about a CONTINUOUS IMPROVEMENT SYSTEM that concurrently achieves Organizational and Individual CHANGE in the uncompromising pursuit of zero.

Questions?