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Representative illustration: After a third fatality in ten years, a steel products maker needed a comprehensive safety program at its 800-person Midwest plant.

Case Study · Mining & Metals

After a third fatality in ten years, a steel products maker needed a comprehensive safety program at its 800-person Midwest plant.

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1Challenge

The plant's OSHA rate was near 11 lost-time injuries per 200,000 hours, against a gold standard near 0.2.

2Approach

  • Started in the finishing department, the plant's most dangerous area, installing a safety management system
  • Built an action-item database of 250+ safety opportunities raised by managers and operators
  • Added a near-miss metric, a safety training capacity plan and 5S

3Results

50%

Reduction in lost-time incidents

27%

Reduction in near misses

96%

Compliance rate on 5S audits

Many safety records have since been broken.

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