Is Safety the 6th S or does it just benefit from a strong 5S program?

February 14, 2013 by Leave a comment

We, like many companies, have adopted lean processes including a 5S program that has been sustained now for many years. In the time that we implemented 5S, OM, VSM and other programs we built ours through our needs and from a search and reapply approach. This meant going to other companies and seeing how they developed their programs to situate their business needs. In doing all of this work you end up seeing so many different approaches of the same model. One of the biggest adaptations was on 5S which also include 6S programs, 7S programs and even one 8S program.

Copy of Maintenance before 1

Our Maintenance Shop before 5S

Sort, Set, Shine, Standardize and Sustain is the English translation of the original 5S model. The basic idea is that you maintain a work space to a level of organization and cleanliness that you create efficiencies by eliminating wastes. The majority of the eliminated wastes are time spent on time looking for tools, moving objects to get to work and organizing the work station for how the work should be done. This includes eliminating clutter, cleaning the machines to “original state” deciding which items are necessary and ensuring they have an efficient home. Quite simply, if completed and done well with employee buy-in then the ultimate goal is to sustain this level and gain efficiencies in the work

Maintenance shop after 4

Our Maintenance Shop5 years after 5S

Over the years many companies saw a significant improvement in safety once implementing the 5S program. The correlation makes sense as well; with the elimination of clutter and oils from machines you eliminate many slips and trips. Additionally if you standardize the work method you can eliminate some repetitive stress injuries. Even other items like proper tool placement with elimination of barriers stopped and prevented many strains and injuries. In following,  safety then  became the 6th S for some and part of this form of this efficiency program.

When reading this your immediate reaction might be that this is perfectly logical. There is an adherent link between the two programs and therefore the combination can save time and resources instead of separating the two and creating redundancies. The issue is though are you providing a strong enough safety program to protect your employees, contractors, visitors and the community?

HS&E programs are becoming more and more stringent on the requirements and additionally strong programs demonstrate excellent payback. While a 6S program would address many risks and hazards it would also leave huge gaps, especially in preventive and administrative programs. Wellness, early return to work, airborne contaminant testing, noise and many other programs do not fit in the simplicity that is the basis of a 5S program.  A company that tries to merge the two runs the risk of either over complicating a 5S program that is to be maintained through operators or worse missing critical areas of a comprehensive HS&E program. So while safety is definitely enhanced when 5S is implemented and the benefits will be immediately demonstrated, to simplify it as the 6th S could put you and your employees at risk.

Cheers,

Lorne

Filed under Continuous Improvements, Health and Safety, Innovation Tagged with , , , , , , , , , , , , , , , ,

Why it’s crucial to invest in good industrial equipment

February 5, 2013 by Leave a comment

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The manufacturing and production industry is one of the biggest industries right across the UK and it plays an important role in producing most of the common foods and items that we see on our shelves day in day out. In the current economic climate, even the manufacturing industry is starting to take a hit and it’s now more than ever that the importance of high quality products and an efficient production floor is noted and taken into consideration across industry manufacturers.

Although manual labour has been a long-term contributor to the success of industry right across the board, in recent years industrial equipment has started to take the place of manual labour with the aim of  bringing costs down and it has started to develop as a crucial contributor to the success or failure of many businesses.

Good industrial equipment can be expensive, but it can also be increasingly productive, so if you are looking to make an investment in industrial equipment it’s crucial that you purchase the right products at the right price. Using this principle here are some key elements that you should take into consideration when investing in the right industrial equipment:

  1. Cheaper is not necessarily better… and yes it might seem like a great idea to invest in the cheapest possible option, especially in tough economic times, but if you buy a product at twice the price which does three time the amount of work then in the long run you could actually be making a saving. Take ALL of the elements into consideration before making your final decision
  2. Reputation counts… and when you are investing in something as important as industrial equipment then buying from a manufacturer with a good reputation can be a great place to start. Many high quality manufacturers have years of experience to build on and in turn you will get a great product
  3. Safety first… in any commercial workplace you need to understand how important it is to put your safety and the safety of your employees first. Workplace claims can destroy a company, so make sure that your business has safety as its #1 priority when you are purchasing any equipment.
  4.  Efficiency can make or break a business… and regardless of what a product costs you need to compare this directly against how efficient the product is. If a product is slow it can slow down your entire production line and quickly de-value the potential speed of more expensive equipment which you might have purchased – so make sure that your equipment is functional for its price.

Filed under Engineering, Helath and Safety, Manufacturing Tagged with , , , , , , ,

All about PAT Testing

November 30, 2012 by Leave a comment

From returning contributor: Grace Beckett

We now live in a digital age where we have become completely dependent on gadgets for our day-to-day activities. There are a lot of problems we encounter with gadgets that sometimes we do not know how to overcome. If we take proper care of our electronics and electrical appliances, they would serve efficiently for a long period of time without breaking down. There are many life-threatening accidents that occur every year due to malfunction of electrical equipment. If we understand the methods to take care of an equipment and acquire the knowledge that helps us test it before use, it would be easier to prevent any casualty to us or to the equipment.

What is PAT?

Portable appliance testing, abbreviated as PAT is a method by which electrical appliances are tested for any malfunction in UK, NZ, Australia and the Republic of Ireland. It protects the safety of an employer against any electrical accidents and certifies an appliance to be compliant with health and safety standards of the state. PAT testing is mandatory in the mentioned countries to increase standards of electrical safety in organizations.

Why is PAT testing necessary?

Most employers are ignorant about the benefits of PAT testing. It helps avoid any risks to health and safety of employees due to faulty equipment. It protects the rights and interests of an employer by reducing the chances of electrically caused accidents in the establishment. A PAT verified equipment is safe for use and will not cause any damage for whatever time specified by the PAT testers.

What kind of equipments need PAT testing?

Any equipment that runs on electricity and connects to an electric outlet through a plug or a power cord needs PAT testing. Hand-held equipments (blow dryer, electric drill, etc.), stationary equipments (refrigerator, oven, etc.), fixed equipments (radiator, air conditioner, etc.), portable equipments (blender, vacuum cleaner, etc.) and moveable equipments (appliances that have wheels and run on electricity) – all need PAT testing.

When are the tests carried out?

The equipments are tested on a quarterly basis or even once in six months. You can hire a professional to test the equipment at your establishment. You could also attend training courses in PAT testing and get certified to test your own equipment.

How is the test carried out?

Usually the test finds faults in equipments through visual inspection method. If you are trained in PAT testing, then you would have a log of all the equipments that might be damaged, like having frayed cables, sparking plugs, etc. There are gadgets used for PAT testing that will present readings for factors like earth continuity resistance, insulation resistance, polarity, etc.  Your training will teach you to interpret these readings in results. All you need to do is combine the results of the PAT test and the visual inspection to determine which equipment is safe for use and which needs replacement or repair.

How do you get trained?

There are many institutes that offer PAT training courses in the United Kingdom. It is easier to get trained than to hire a professional test your equipment, as the latter can be quite expensive.

Grace is an expert associated with PASS Ltd., a company that specializes in providing PAT testing courses all across UK.

Filed under Helath and Safety, Human Resources Tagged with , , , , , , ,

Being Safe is Part of Enjoying Summer

July 13, 2012 by 2 Comments

We are in the middle of the summer and for a lot of companies this is a slower period due to vacations and high temperatures that really can wear down employees. Due to this you run a high risk of accidents and injuries as we continue to strive to meet the customers’ demands.

As employers we must be aware of issues like heat stroke, employees compensating for reduced staff and even lack of attention as they are thinking ahead to the trip to the lake. Some ways to ensure that employees are safe is to discuss the potential risks daily, increase breaks, provide plenty of water and as leaders spend more time on the production floor observing the work environment and address any risks immediately.

Summer is a great time for everyone to take a break and get the rest and fun we earned through working hard the rest of the year. So make sure that it is enjoyable holiday by not having to spend it in the hospital or worse. This starts in fostering a safe work place and continues when we leave and by having a safe and enjoyable summer.

 

Cheers,

Lorne

Filed under Business, Health and Safety, Human Resources Tagged with , , , , , , ,

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