Case study · Mining & Metals
Steel products maker cuts lost-time incidents 50% with a new safety system
A maker of steel products for the oil and gas industry asked USC to build a comprehensive safety program at its 800-person Midwestern plant. Lost-time incidents fell by half and near misses by 27%.
Results
50%
reduction in lost-time incidents
27%
reduction in near misses
Many plant safety records were broken after installation.
The situation
The 800-person plant carried an OSHA rate near 11 lost-time injuries per 200,000 hours worked, against a top rate near 0.2, and had suffered a third fatality in ten years.
What the assessment found
- Weak safety data capture and prioritization of initiatives
- Finishing department the most dangerous area in the plant
- Culture and behavior not yet focused on safety
How the work was done
System: start in finishing
Installed a safety management system starting in the finishing department, the plant's most dangerous area.
Actions: track every fix
Built an action-item database of more than 250 safety improvements raised by managers and operators, used to prioritize, plan and complete corrective actions.
Metrics: measure near misses
Reviewed safety metrics at every management level and set a baseline for a new near-miss metric.
27%
reduction in near misses
Workplace: apply 5S
Implemented 5S to remove waste and improve flow, and planned training resources and capital for long-term safety.
96%
compliance with 5S audits
“Ensuring the safest possible work environment for our employees is paramount to the company's leadership team. To the degree we have succeeded, we have USC Consulting Group to thank.”
Lasting impact
Many plant safety records fell after the system was installed, and the joint plant and USC team built a safer work environment.
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