Safety and Go Together - crops.extension.iastate.edu · Safety and Quality Go Together Gretchen A....
Transcript of Safety and Go Together - crops.extension.iastate.edu · Safety and Quality Go Together Gretchen A....
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Safety and Quality Go Together
Gretchen A. Mosher, PhDAAI Showcase,
Grain and Feed Forum
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When does quality matter?
Source: Grain Journal Nov 4 2010
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Managing more than quality
QUALITY
Security
Speed
Cost
CustomersCompliance
Safety
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Quality is one of many concerns• Customer service• Speed/ Productivity• Personnel safety • Food safety• Profits • Biosecurity• Site security• Environmental
Quality directly impacts storage, marketability, and end use!
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Quality Management Systems
QMS are• Disciplined structures for organization of production
• Require structured format for documenting
• Focus on consistency and repeatability
QMS are not• Strict standards on what to do and not to do
• Inflexible • Generic checklists / audits
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Quality management in agriculture
• Respond to security regulations (food safety, environmental, bioterror)
• Increased operating efficiency• Better ability to meet customer demands• Tighter control and management of inventory• Better definition of processes• Poor decisions mean lost profit!
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Safety in the Workplace• Preventing injury and fatalities is a continuing challenge
– 4,547 recorded occupational fatalities in 2010 (BLS, 2011)– 3 million cases of non‐fatal occupational injuries reported in 2010, with nearly 2 million requiring day off work , job restriction or job transfer
– Fatality and injury rates in agriculture higher than other industries – 37 per 100,000 vs. 3 per 100,000
• Majority of fatalities and injuries occur as a result of:– Employees actions– Taking shortcuts & not following procedures
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How important is safety?• Reduces absences and days lost to injury• Decreases insurance premium costs • Enables enterprises to meet and exceed
customer expectations• Increases motivation and the commitment
of employees to the business • Mistakes are expensive!
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Safety and quality are a lot alike• Common characteristics:
– Driven by management, often top‐down– Focus on continuous improvement– Training procedures and standardized operating procedures play important role
– Emphasis is on prevention rather than reaction• Several processes can be used in both applications
– Process documentation– Improvement and standardization of processes– Statistical process control– Decision‐making based on data, trends, and evidence
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Addressing Safety and Quality with QMS
• Recall QMS does not tell you what to do• Use to increase consistency and repeatability in processes – safety and quality
• Knowledge about your organization and its processes helps in decision‐making:– Receipt, storage, shipping options to preserve quality
– Safety procedures– Compliance documentation
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Constraints??
PEOPLE!PEOPLE! PEOPLE!
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People Connections Between Safety and Quality
• Safety is a more fundamental need than quality
• Workers who feel unsafe will not make quality a priority
• Both are dependent on employee actions• Employee actions may be controlled by limits of the system
• Perceptions are important to success of programs
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More connections
• Quality guru Deming saw safety and quality as complimentary workplace goals
• Based on Maslow’s Hierarchy of Needs
Safety Quality
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Safety & Quality in Agriculture• Out‐of‐condition grain has been cited as a major factor in engulfments
• Poor quality grain:– Does not handle or convey well – Uses more power & capacity– Attributed to:
• Shorter “shelf life”• Food safety issues (mold, damage)
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Interactions Between Safety & QualityEngulfments infrequent and low profile but entirely preventable2010 ‐ record number of engulfment incidents Higher number at commercial grain elevators than previouslyHigh fatality rates
• 1969 – 1995, 80% (Freeman et al, 1998) • 1964‐2005, 74% (Roberts & Field, 2010)
Corn primary entrapment medium
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Out‐of‐condition grain
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Connections in Employees’ Minds• Do employees see safety and quality as parallel or complimentary goals?– We asked about 180 employees from three elevator companies in Iowa
– Do these feelings differ for different personnel?• Managers – set safety and quality policies• Supervisors – implement and enforce safety and quality policies
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Safety & Quality ‐Management
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Perceptions of Quality
Relationship between perceptions of management's commitment to safety and quality
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Safety & Quality ‐ Supervisors
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Relationship between perceptions of supervisor's commitment to safety and quality
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Data on Strength of Relationships• Employees perceived a very strong relationship between safety and quality
• Stronger quality feelings about management than supervisors
• Follows theory from safety and quality experts• To increase likelihood of success of quality programs, engage your supervisors in quality management!
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Wrapping up …
• Quality can and should be integrated with other workplace goals
• Workers will not focus on quality outcomes unless their safety needs are met
• In grain handling, high quality grain prevents safety incidents
• Safety and quality are strongly linked in employees’ minds
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Safety
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Thank you for your attention. Questions?
Gretchen A. Mosher, PhDIowa State University