Improving Productivity, Quality & Safety

Using Pipe Markers To Improve

2010-03-30T12:52:00.000-07:00

What is a pipe marker?

It is simply a label applies to a pipe that identifies the contents, type of hazard and the direction of flow of the contents of the pipe. The label color shows the type of hazard. Arrows indicate the direction of flow. An text printed on the label identifies the contents of the pipe.

There are codes that set the standards used for pipe markers. Standard colors must be use. There is a minimum size for the label, and the text on the label, based on the diameter of the pipe. The code that most often applies is the ANSI A13.1 pipe marking code. Other codes cover specialized applications such as ammonia refrigeration pipes, medical gas pipes, and pipes on ships.

Pipe markers are not only required by code, they improve productivity by providing needed information at the point of need. For example, knowing the direction of flow can be critical for knowing which valve to close to shut off that flow. And knowing the contents of each pipe helps ensure the correct valve is closed.

A pipe marking best practices guide from Graphic Products provides all the information you need about pipe marker design, printing and application. It's available free.

Less Chaos, More Cash

2010-01-01T08:27:00.001-08:00

It's been awhile since my last post, but it's been a while since I found something that is truly of value for improving quality, productivity and safety... and earning you more money. It seems everyone has been playing defense this past year.

A new book by Aaron Crowley, called Less Chaos, More Cash provides solutions to problems that are holding most small business back. Learn how you can overcome challenges you may not even be aware of. Aaron clearly defines problems and provides clear, simple to implement solutions that can bring small businesses greater profitability.

“An enjoyable, candid journey of running a growing small business. Aaron’s book is a must have, quick read that will help entrepreneurs grow faster and avoid the common pitfalls we all face. It’s insightful, enjoyable, and time well spent.”

—Keith Voigt, President, Great Western Ink

Installing Granite Tile - Improving Productivity At Home

2009-01-24T09:06:00.001-08:00

It used to be that do-it-yourself granite tile installation was impossible, or difficult at best. The problem is that tile does not come with finished edges. Because each installation is a custom installation, granite tile (or marble, stone or other natural material) can not be pre-finished. That means for the do-it-yourselfer the tile had to be hand finished, and the quality of the result was a problem. That took A LONG TIME. And why install luxurious granite counters and not have high quality, finished edges?

A new company, Easy Granite Tile, has solved both the productivity and quality problems. They provide custom granite tile that can be easily ordered on the internet. They have developed a unique tile online calculator that will determine the amount of tile needed, the amount of edging required, and the total cost. It is fast and easy.

Once you've seen what is needed you can place your order online. Easy Granite Tile will express ship a sample of the tile you've selected so you can be sure the color and quality are what you want.

The they'll make the tile for your kitchen. But even in this process there is a difference. When you hire a professional to install your tile, the edges will still be finished by hand. Quality can vary. Easy Granite Tile has developed an automated system of tile edging that creates perfect tile edges every time. You'll get superior quality, and you can install it yourself.

Visit their web site today and learn how you can enhance the value of your home, and do-it-yourself!

Workplace Safety Blog

2009-01-22T03:00:00.000-08:00

There is a safety blog that looks at safety news from a slightly different perspective. I'm not sure how to describe it. It often features tools for improving safety training, most of which are free. It sometimes has political news related to safety. But in general it seems to provide news that is related to breaking trends in workplace safety.

This blog is a part of the Safe Workplace web site. Use this link to go to the Safe Workplace Blog.

Five Steps To A Visual Workplace

2008-02-08T10:34:00.000-08:00

Here is a link to the Five Steps To A Visual Workplace.

On this one page you see what it takes to create a visual workplace such that even new employees know where they are, what is around them, and what they need to do. A visual workplace provides the information people need, right at the point of need.

Preparing For A VPP Audit

2008-02-01T05:14:00.000-08:00

OSHA's Voluntary Protection Program (VPP) recognizes workplaces that have outstanding safety practices and records. However, even for workplaces with top notch safety records, becoming a member of VPP requires years of effort, including documentation of training and work practices.

One of the major steps in attaining VPP status is the VPP audit. One of the key things a VPP audit will look for is the comprehensive and consistent use of labels and signs--what is called visual communication. Not only the labels and signs required by code, but having a complete visual communication system in place such that everyone can immediately know where they are, what is around them (including hazards), and if action is required, what they need to do.

Most of us are familiar with the need to label pipes and valves such that wherever you are standing, if a pipe is visible you can see a label that identifies the contents, direction of flow and hazard level. However, a visual communication system takes this a step further. For example, the information on each valve would also describe when the valve should be opened or closed.

Be prepared for your VPP audit by setting up a VPP Labeling Cart that has all the supplies needed to make the labels and signs your facility needs. A VPP cart should include a label printer, such as the DuraLabel PRO, a PC to keep track of the labels and signs in your visual communication systems, all of the needed labeling supplies, including sign blanks and valve tags, and any other materials or supplies that might be needed such as plastic ties, scissors, a knife, tape and other tools.

What Is A Visual Workplace?

2008-01-31T11:02:00.000-08:00

A new set of web sites (the owner's call them a web site suite) aimed at lean manufacturing topics has just come online. They are based on the concept of the visual workplace.

What is a visual workplace?

A visual workplace has to do with having everything in the workplace marked and labeled such that a new employee can find something as easily as an experienced employee. This does not mean that there is a label on EVERYTHING. What it does mean is that needed information is provided right at the point of need, usually by using a label or sign.

Visit the www.LabelPrinter.com web site to learn more about a visual workplace.

Three subdomains are a part of the www.LabelPrinter.com "web site suite". They each focus on a specific lean manufacturing method: kaizen, 5S and kanban. Coverage of additional lean methods is promised for the future.

Man Injured By Falling Beer Can

2007-11-30T06:57:00.000-08:00

There is an interesting post on the Safe Workplace blog about a man who went to a grocery store to purchase a four-pack of beer. One of the beer cans slipped free from the plastic ring, falling and hitting the man. He is now suing the grocery store, brewer and beer distributor for the resulting serious injury. The suit includes costs for hospitalization, nursing home care, permanent loss of income and much more. You've got read this one.

OSHA Unveils a New Publications Web Page

2007-11-21T11:59:00.001-08:00

The Occupational Safety and Health Administration (OSHA) today unveiled a new Publications page on its Web site at www.osha.gov that allows visitors to access OSHA's resources in an efficient and user friendly way.

"The OSHA Publications page is one of the most popular pages on the agency's Web site. In fact, the agency's Publications page receives more than 300,000 visits per month," said Assistant Secretary of Labor for OSHA Edwin G. Foulke, Jr. "The page was redesigned in an effort to make the site's content easier to access, while maintaining OSHA's commitment to providing valuable safety and health materials."

OSHA undertook the redesign to give the Publications page a more user-friendly look and feel, and to make the page the comprehensive resource for the agency's extensive number of safety and health products. Visitors may now search by the publication number or keyword; from an alphabetical listing; by industry or topic, and by type of publication. In addition to new releases, the revamped page highlights publications "Recommended by OSHA" that may interest visitors and "Most Frequently Viewed OSHA Publications."

The new design is based on feedback from OSHA customers. Visitors may order up to 25 copies of up to five publications using the new ordering capability. This feature is similar to "shopping carts" found on commercial Web sites and helps visitors keep track of the publications they are ordering and the number of copies ordered.

OSHA Statement On 2006 Occupational Injuries and Illnesses with Days Away from Work

2007-11-15T06:59:00.000-08:00

U.S. Secretary of Labor Elaine L. Chao issued the following statement regarding data published on Nonfatal Occupational Injuries and Illnesses Requiring Days Away from Work in 2006, http://www.bls.gov/news.release/osh2.nr0.htm. The report, announced by the U.S. Department of Labor's Bureau of Labor Statistics (BLS), provided detailed information on the continued decline in the rate and the number of workplace injuries and illnesses in private industry that required recovery away from work.

"This report shows that, from 2005 to 2006, there was a six percent reduction in the rate of lost time injuries and illnesses, as well as a four percent reduction in the overall number of those injuries and illnesses, both of which represent significant improvements. We now also have new data on selected injury and illness rates by occupation, gender and age group that helps us identify those employers and employees who most need our assistance.

"The U.S. Department of Labor's programs to keep America's working men and women safe and healthy are achieving the desired results — more men and women are going home safe and whole at the end of the workday. However, we will not rest on this positive news; we will continue to work to ensure the safety and health of the nation's employees through compliance assistance; partnerships and cooperative programs; and strong, fair, and effective enforcement."

Rakes and Pains

2007-11-13T12:11:00.000-08:00

Leave raking injuries behind with these safety tips

Press Release From AAOS

Autumn leaves look beautiful on trees, but less so once they fall. That is because leaves on the ground mean it is time to start raking. This outdoor task is often more physically demanding than people realize, so the American Academy of Orthopaedic Surgeons (AAOS) recommends that people take precautions when raking.

Even though raking does not utilize power tools or sharp blades, it can still cause injuries. According to 2006 U.S. Consumer Products Safety Commission statistics, more than 76,000 people were treated in hospital emergency rooms, doctors’ offices, clinics and other medical settings for injuries related to non-powered garden tools, including rakes.

"Many people consider raking just another chore, but it requires a lot more reaching, bending and lifting than most odd jobs," says Daryll C. Dykes, MD, PhD, orthopaedic surgeon and spokesperson for the Academy. "Raking should be treated like any other vigorous exercise. People should pay close attention to their arms and backs, being careful not to reach or stretch too far."

The Academy offers the following recommendations to prevent injuries while raking:

With any physical activity, it is important to warm up your muscles for at least 10 minutes with light exercise and stretching, especially when it is cold outside. You should also stretch your muscles after raking to relieve tension and prevent soreness.
Use a rake that feels comfortable for your height and strength. Wear gloves or use rakes with padded handles to help prevent blisters.
Avoid using old rakes that have gotten rusty or that have loose or broken parts.
Do not let a hat or scarf block your vision. Watch out for large rocks, low branches, tree stumps and uneven surfaces.
Try to vary your movements, alternating your leg and arm positions often. When picking up leaves, bend at the knees, not the waist.
Exercise care walking on wet leaves, which can be very slippery. Avoid falls by wearing shoes or boots with slip-resistant soles.
Avoid overfilling leaf bags, especially if the leaves are wet. You should be able to carry bags comfortably, so make sure they aren’t too heavy or large.
Do not throw the leaves over your shoulder or to the side. This requires a twisting motion that places undue stress on your back.

For more information on exercise- and sports-related injury prevention, visit:
http://www.orthoinfo.org/category.cfm?topcategory=Injury%20Prevention

Graphic Products' Sponsors Shingo Sweepstakes

2007-11-08T06:55:00.000-08:00

Graphic Products, a leading supplier of label and sign printers, is one of the sponsors of the Shingo Sweepstakes, a lean manufacturing sweepstakes that started on November 6th and runs through the end of April 2008. $25,000 in prizes will be given away.

No purchase is required to enter the sweepstakes.

The purpose of the sweepstakes is to promote lean manufacturing and the Shingo Prize. The Shingo Prize is regarded as the premier manufacturing award recognition program for North America. The Shingo Prize promotes world-class business and manufacturing processes that will enable organizations to achieve perfection in quality, best cost, and 100 percent on-time delivery to fulfill the customer experience. It also promotes the sharing of "True North" core business and manufacturing processes for continuous improvement. The Shingo organization recognizes research and applied materials that support the vision and mission of the Shingo Prize. The Shingo Prize achievement criteria provides a framework for identifying and evaluating world-class manufacturing competence and performance.

Graphic Products is not in the business of selling lean manufacturing products. But, having seen the benefits of lean manufacturing they have been offering resources to help their customers improve business performance through lean manufacturing techniques. Graphic Products offers a number of free lean manufacturing guides. No purchase is required to request any of these guides:

5S Quick Start Guide

5S Standard Color Coding Guide

Kanban Quick Start Guide

Kaizen Quick Start Guide

2007 America’s Health Rankings Show a Decline in the Overall Health of the Nation

2007-11-06T12:05:00.000-08:00

The following is a press release from American Public Health Association.

Analysis shows Vermont, Minnesota and Hawaii are nation’s healthiest states; Mississippi and Louisiana rank as least-healthy states

WASHINGTON, D.C. – November 5, 2007 – The overall health of the nation declined over the past year, despite progress made in several key health indicators, according to a report launched today by United Health Foundation, the American Public Health Association (APHA) and Partnership for Prevention. The 18th annual edition of America's Health Rankings: A Call to Action for People & Their Communities measures the overall healthiness of states and the nation using a comprehensive and longitudinal set of related health determinants and health outcomes. The report indicates that the overall health of the nation declined by a rate of 0.3 percent since last year.

While this report, and others, show there have been modest gains in reducing the rates of cancer and cardiovascular mortality, these improvements continue to be dwarfed by increasing obesity, increasing numbers of uninsured people, children in poverty and the persistence of risky health behaviors, such as tobacco use and violent crime -- all of which have a significant impact on the overall healthiness of the nation.

"Even though specific mortality rates have improved, this report shows there are still many people who, through unhealthy personal behaviors, adverse community environments and difficult access to care, are vulnerable to a future life of poor health -- which is essentially preventable," said Reed Tuckson, M.D., member of the board of United Health Foundation. "The consequence of this reality manifests itself in a poor quality of life, people living with chronic disease, compromised productivity and significant escalation in the costs associated with managing chronic illness."

This lack of progress is in sharp contrast to the nation's average annual improvement of 1.5 percent between 1990 and 2000. In fact, since 2000, there has been a virtual stagnation in health improvement. The failure to demonstrate progress is particularly worrisome given that the U.S. continues to trail other nations in important health indicators such as infant mortality and healthy life expectancy.

Once again, this year's report provides a ranking of the healthiness of each state. Vermont surpassed Minnesota as the healthiest state in the nation this year, with Minnesota (2), Hawaii (3), New Hampshire (4) and Connecticut (5) rounding out the top five.

The data also notes that Mississippi ranks as the least healthy state, with Louisiana (49), Arkansas (48), Oklahoma (47) and Tennessee (46) completing the bottom five. The publishers of the report note that every state – no matter its ranking – has its own set of unique challenges to confront and successes on which to build and from which other states can learn.

A National Health Analysis

This year the report analyzes a comprehensive set of 20 related health measures, such as smoking, binge drinking, violent crime, infectious disease, high school graduation, health status and several measures of mortality. The analysis of this comprehensive set of factors allows for a more complete and holistic view of the health of the nation than only death-related statistics. The following is a snapshot of the national findings:

Since the first report in 1990, America’s Health Rankings, using a consistent set of measures, has shown an 18.4 percent improvement in the nation's overall health. This national success can be attributed mostly to:

The reduction of several health determinants, such as infectious diseases, smoking, infant mortality, cardiovascular deaths and violent crime.
Fewer children living in poverty.
More ninth graders graduating high school within four years now than in 1990.

Over the last six years, however, the nation’s health has virtually stagnated. Several reasons for the stagnation are obesity, a growing number of uninsured and persistent lack of progress in key health measures such as tobacco use, violent crime and children in poverty. Within the national environment, some states have addressed key health issues and improved, however others have not and are declining.
Obesity has increased from 11.6 percent of the population in 1990 to more than 25 percent today. More than 55 million Americans are obese and as a result are at significant risk for other diseases, such as heart disease, diabetes, stroke, and cancer.
According to the U.S. Census Bureau, the number of Americans who are uninsured has increased from 13.4 percent in 1990 to 15.8 percent of the population today. Up .5 percent from last year, an alarming 47 million Americans are living without health insurance. Tragically, more than nine million of the uninsured are children. According to the Institute of Medicine (IOM), people without health insurance are sicker and die sooner. IOM attributes 18,000 deaths per year to people under age 65 due to lack of insurance coverage.

The United States Compared to Other Nations

This year's report also looks at the U.S. compared to other nations. According to the 2007 Commonwealth Fund findings, the U.S. spends twice as much on health care than Australia, Canada, Germany, New Zealand and the United Kingdom. Despite this expenditure of health care assets, the U.S. continues to fall behind in several important indicators of health. For example:

Although the U.S. can now celebrate its highest life expectancy in history (77.9 years), 43 other countries still have life expectancies that are higher than the U.S., including Japan, Sweden, France, Canada, Italy and Australia. In fact, a baby born today in Japan has a life expectancy of 82.0 years and a baby born in the U.S. has a life expectancy of 77.9 years. If we look at a broader measure and compare healthy life expectancy – that is number of years of active, healthy life expected at birth – a baby girl in Japan can expect 78 years whereas a girl born in the U.S. can expect only 71 years of healthy life at birth. Once again, U.S. citizens continue to demonstrate unacceptably high burdens of illness.

"The health of the American people is not just about length of life, but it is also about quality of life," said John Clymer, president of Partnership for Prevention. "We must look to each other, but also to these other nations as examples to aid us in our efforts to improve health."

State-by-State Analysis

Several states exhibited noteworthy gains in overall health improvement. For example:

South Carolina had the highest overall health improvement with a 6.3 percent increase. Montana followed with a 4.6 percent increase, and Maryland and New Mexico both had a 4.5 percent increase in health status.
Vermont moved to the top of the list of healthiest states after a steady climb in the rankings for the past seven years. This is notable because it demonstrates that progress can be made. Vermont has made significant progress in several key areas:

The prevalence of smoking declined from 21.5 percent in 2001 to 18.0 percent in 2007.
Children in poverty declined from 16.1 percent in 2001 to 8.9 percent of persons under age 18 in 2007.
In 2001, Vermont ranked only 29th in prenatal care – now it ranks 2nd.

Nebraska’s return to the top ten (it last appeared in the top ten in 1992). Nebraska notes a continued improvement in high school graduation rates – now the highest in the U.S. Nebraska also has experienced reductions in the last few years in the occupational fatality rate and violent crime.
After four years in the bottom ten, Georgia moved up to 40th place. Georgia has experienced a decline in the infectious disease rate, number of poor physical health days and prevalence of smoking.

Health Disparities among Populations

Given that America’s Health Rankings™ is specifically intended to provide opportunities for focused analysis and action to meet high priority local problems, documenting disparities in health status between populations has been, and continues to be, a major feature of the report. Once again, state-specific concerns are noted and national trends also are documented.

Disparities continue to exist in measures such as premature death (premature death measures the loss of life before age 75 in a population). The premature death rate for Blacks is almost 1.5 times than the rate for Whites.
Disparities also are growing between the Hispanic and non-Hispanic populations.
According to the National Healthcare Disparities Report, Hispanics receive poorer quality care than non-Hispanics and data indicates that this trend is getting worse, not better.
In terms of preventive care, the Hispanic population has the lowest percentage of people accessing regular dental care and colon cancer screenings – two key indicators of a population’s ability to stay healthy.

"Eliminating disparities in health requires a greater emphasis and focus on the root causes of poor access to care; differential access to quality medical care; and the social determinates that lead to unhealthy living conditions," said Georges C. Benjamin, M.D., FACP, FACEP (E), executive director of APHA. "Eliminating these disparities is a mechanism to improve the overall health status of the nation and advance our health rankings as compared to the rest of the world."

To view the entire report, please visit www.americashealthrankings.org or www.unitedhealthfoundation.org.

CPSC Acting Chairman Issues Statement on Letter to Congress

2007-11-01T07:39:00.000-07:00

WASHINGTON, D.C. - October 31, 2007 This week, several members of Congress publicly called for my resignation as CPSC Acting Chairman, citing a letter I recently sent to the Senate Commerce Committee expressing my views on pending legislation before that committee. In the letter (pdf), I respectfully pointed out what I think are several unwise proposals in a bill to reauthorize and expand the mission of the CPSC. However, despite media reports to the contrary, nowhere in the letter (or anywhere else) did I assert that the CPSC does not need additional resources. In fact, quite to the contrary, the main message of the letter is that if CPSC resources are diverted to new missions and mandates, we will need a dramatic upsurge in our personnel and funding, far beyond what either the House or Senate are proposing for our pending budget. Nor have I ever asserted that the agency does not need new legal authority. Again, the opposite is true. In July I submitted to Congress a legislative package seeking no fewer than 40 new statutory enforcement tools and other changes to enhance our ability to protect the public from unsafe products. To date, the Committee has only seen fit to adopt a few of those proposals.

I am very troubled by the prospect that any time a federal agency official is critical of legislation pending before Congress, congressional leaders may seek to have that official silenced or even dismissed. At the request of the committee, and as follow-up to a meeting I had with committee staff, I provided what I and the agency's senior staff believed were honest, constructive and apolitical comments and suggestions on a bill that could have a dramatic effect on our agency and our ability to carry out our core mission.

I do not intend to resign because I care passionately about the mission of this agency. However, I am saddened and troubled by the tactics being used in an attempt to silence debate on important policy issues.

Classic Safety Video

2007-10-31T19:42:00.000-07:00

A classic safety video spoof, Klaus, First Day On The Job, has been made available on the Safe Workplace Blog.

This "safety" video shows Klaus, an employee who has just received his forklift driver's license, as he goes through his first work day. As the day goes on the accidents become more serious, and bloodier. This is not a video for those who do not like the sight of blood.

A Quick Start Guide to Auto Darkening Welding Helmets

2007-08-05T00:14:00.000-07:00

Article By:Steve Bishop

If you are a welder you are most likely concerned with your safety. You take precautions by wearing a helmet while welding, but what type of helmet do you have? The type of helmet you wear can greatly affect your eye safety. Welders are all too familiar with the possibility of an arc flash. Exposure to the intense arc flash can cause serious harm to your eyes including retinal burns. Therefore, it is imperative to find an auto darkening welding helmet.

What should you look for in an auto darkening welding helmet? First, verify that the helmet meets the ANSI Z87.1 standard. This standard guarantees that the helmet will provide the proper protection against the arc flash. You can choose a lens shade that will suit your comfort level and needs. Ensure that you wear the helmet properly in the down position when you weld.

Welding helmets can change shade by solar powered or battery operated means. What are the differences between these two methods? Solar powered shades change when a change in light intensity is detected. They are designed to automatically darken from the arc. Battery operated shades must be turned on by the welder to operate like the solar powered shades.

Helmet specifications can be analyzed before making a purchase. You can research specifications including viewing area, UV/IR protection, switching speed, power supply, operating temperature, weight, price, and much more. More detailed information regarding each specification can be found on many manufacturers’ websites.

Find a helmet that feels comfortable atop your head for extended periods of time. You might want to invest in a helmet that has a sensor bar if you work in close proximity of other welders. The sensor bar will help to alleviate any false alarm darkening of your helmet due to neighboring welders.

Where can I find an auto darkening welding helmet? Auto darkening welding helmets are sold through many stores, online retailers, and even on Internet auction websites such as eBay. Prices can range from under $100 to over $200. Helmets are produced by different manufacturers and contain a wide range of features. You can even purchase a helmet called the Hobart Hood Premium 770262 Auto-Darkening Welding Helmet. It comes in a Stars & Stripes version. This helmet has the American flag painted on it.

There are plenty of Internet resources available to search for your perfect welding helmet. You can find welding helmets that align with your welding duties. An array of options is at your fingertips.

If you are a welder you are most likely concerned with your safety. You take precautions by wearing a helmet while welding, but what type of helmet do you have? The type of helmet you wear can greatly affect your eye safety. Welders are all too familiar with the possibility of an arc flash. Exposure to the intense arc flash can cause serious harm to your eyes including retinal burns. Therefore, it is imperative to find an auto darkening welding helmet.

What should you look for in an auto darkening welding helmet? First, verify that the helmet meets the ANSI Z87.1 standard. This standard guarantees that the helmet will provide the proper protection against the arc flash. You can choose a lens shade that will suit your comfort level and needs. Ensure that you wear the helmet properly in the down position when you weld.

Welding helmets can change shade by solar powered or battery operated means. What are the differences between these two methods? Solar powered shades change when a change in light intensity is detected. They are designed to automatically darken from the arc. Battery operated shades must be turned on by the welder to operate like the solar powered shades.

Helmet specifications can be analyzed before making a purchase. You can research specifications including viewing area, UV/IR protection, switching speed, power supply, operating temperature, weight, price, and much more. More detailed information regarding each specification can be found on many manufacturers’ websites.

Find a helmet that feels comfortable atop your head for extended periods of time. You might want to invest in a helmet that has a sensor bar if you work in close proximity of other welders. The sensor bar will help to alleviate any false alarm darkening of your helmet due to neighboring welders.

Where can I find an auto darkening welding helmet? Auto darkening welding helmets are sold through many stores, online retailers, and even on Internet auction websites such as eBay. Prices can range from under $100 to over $200. Helmets are produced by different manufacturers and contain a wide range of features. You can even purchase a helmet called the Hobart Hood Premium 770262 Auto-Darkening Welding Helmet. It comes in a Stars & Stripes version. This helmet has the American flag painted on it.

There are plenty of Internet resources available to search for your perfect welding helmet. You can find welding helmets that align with your welding duties. An array of options is at your fingertips.

Article Source: http://www.redsofts.com/articles/

Click Here To Discover more About Auto Darkening Welding Helmets

30-minute CPR Classes Just As Effective As Multi-hour Courses

2007-07-30T07:49:00.000-07:00

UT Southwestern Medical Center researchers have found that a user-friendly, 30-minute, video-based cardiopulmonary resuscitation training session is just as effective as the traditional three- to four-hour course in teaching basic life-saving techniques to laypersons. In addition, at six months after the training — a critical point for CPR skill retention — those who took the shorter course performed CPR and used an automated external defibrillator (AED) just as well or better than those who take the traditional training.

These findings, published in the August issue of the journal Resuscitation, are the first to evaluate and document the effectiveness of long-term retention of the new 30-minute CPR-AED training.

“The results of this formal investigation should not only facilitate more widespread training and frequent re-training in CPR techniques, but it also diminishes some of the inefficiencies and labor-intensity inherent in traditional CPR training,” said Dr. Paul Pepe, chief of emergency medicine at UT Southwestern.


	Dr. Lynn Roppolo (right), assistant professor of emergency medicine, and Dr. Ahamed Idris, professor of emergency medicine, were part of a group of researchers who have found that a user-friendly, 30-minute, video-based cardiopulmonary resuscitation training session is as effective as the traditional three- to four-hour course in teaching basic life-saving techniques to the public.

Traditional CPR courses last half a day, as six to eight people take turns practicing their skills on a shared manikin. The remainder of the time is spent listening to instruction, leaving little time for skills practice, the researchers report.

“Using individualized kits, the trainees can focus on uninterrupted skills practice and develop muscle memory from more intensive, focused and reiterative practice,” said Dr. Pepe.

The shorter course is much more convenient and easily accessible, said Dr. Lynn Roppolo, assistant professor of emergency medicine and lead author of the study.

“Individuals practice while they learn, allowing more time to perform and retain the critical hands-on skills required to provide more effective CPR,” Dr. Roppolo said. “All of these factors will likely translate into more people knowing what to do — and doing it right — whenever CPR is needed. As a result, hopefully, many more lives will be saved in years to come.”

For the study, volunteers recruited in Fort Worth were selected randomly to take either the 30-minute course or a traditional three-hour session.

The short course consisted of a 23-minute digital video disc program, developed by the American Heart Association, which covers basic adult CPR skills, including recognition of signs of life, calling for help, opening the airway, rescue breaths and chest compressions.

As two dozen or more students watched the video in each session simultaneously, they practiced the CPR techniques almost continuously for nearly 20 minutes on their own personal mini-manikin, supervised by a “facilitator” who generally only needed to answer an occasional question from the trainees once the DVD was started.

Also included was a three-minute discussion and demonstration on the recognition of and best procedures for choking, as well as a five-minute demonstration of the use of an AED.

In the traditional course, students attended a three-hour session consisting of lectures supplemented by related video-based instruction, practice of basic CPR skills, choking procedures and instruction and hands-on practice in the use of an AED. During this course, there was one certified instructor for every six to eight students during the skills practice.

After their respective training, the students from both groups were tested using a life-sized manikin, which was connected to a laptop computer that objectively measured parameters such as the rate and depth of ventilations and chest compressions.

In addition to the computer measurements, overall CPR performance and AED use were videotaped and later judged as being appropriate by CPR training experts, who graded each study participant without knowing whether the he or she had taken the half-hour course or the traditional training.

Immediately after taking the class, there were no significant differences in CPR performance between the students who took the three-hour course as compared to those who took the 30-minute course.

After six months, however, trainees who took the 30-minute course called 9-1-1 and provided adequate ventilation more frequently than those who took the longer course. Also, both at the initial and six-month follow-up test, the students who took the traditional course took 30 percent longer to assess for signs of life, and they took significantly more time to pause between chest compressions to perform ventilations.

In grading AED use immediately after the courses, the trainees who took the 30-minute course placed the AED pads and delivered a shock correctly in 98 percent of the cases, compared to 92 percent of those who took the longer course. Moreover, at the critical six-month follow-up, 93 percent of those in the half-hour course still operated the AED well and 93 percent were still judged to be performing chest compressions adequately.

“The results of this investigation were very compelling. This study suggests that hands-on practice is not necessary to learn how to operate an AED, a device that directly provides the rescuer with vocal instructions once it is turned on,” said Dr. Roppolo. “Thus, training tools that utilize cognitive modes, such as the Internet and DVD demonstrations, may be just as effective.”

Other UT Southwestern researchers contributing to the study included Dr. Ahamed Idris, professor of emergency medicine, and Dr. Ronna Miller, assistant professor of emergency medicine.

The research was supported by the American Heart Association, the Laerdal Medical Corp., and Phillips Medical Systems and American Airlines.

Safety In China

2007-07-19T07:10:00.000-07:00

News about Chinese products and foods, exported to other countries, causing health problems seems to be in the news almost daily. However, an even bigger problem is that of product safety within China. It's a country in which safety is of secondary (or even tertiary) importance to the number one objective of making money.

An example is reported in today's issue of the International Herald Tribune. Over a period of just two days, last Sunday and Monday, there were three accidents involving the manufacturing of explosive devices by home businesses. You can read the article at:

http://www.iht.com/articles/ap/2007/07/18/asia/AS-GEN-China-Blast-Deaths.php

Free Lean Manufacturing Guides

2007-07-12T10:46:00.000-07:00

Several lean manufacturing guides are available free for the asking. The cover areas such as 5S, kaizen and kanban. Here are some links:

A free guide to standard 5s colors shows the color coding system that has developed for use with 5S. There is no organization that establishes standards for 5S, but this color coding system has come about as a result of common usage.

There is also a free guide to implementing 5S available. It provides a quick overview of 5S, describing what it is, the benefits of 5S, and how to start your own 5S program.

If you'd like to learn about kaizen, a kaizen quick start guide is available from a poster printer web site. Poster printers are used to enlarge 8-1/2" x 11" originals to poster-sized. They provide a quick and convenient way to create visuals to support all of your lean manufacturing efforts.

Kanban is a method for reducing costs and waste, and improving quality and productivity by improving your logistics. It is often assocated with JIT (Just In Time) delivery, which is a key component of lean manufacturing. A free introductory guide to kanban is available from the Facility Signs web site.

FDA Clears First Respirators for Use in Public Health Medical Emergencies

2007-07-05T15:07:00.000-07:00

The U.S. Food and Drug Administration (FDA) today cleared for marketing the first respirators that can help reduce the user's exposure to airborne germs during a public health medical emergency, such as an influenza pandemic.

These two filtering facepiece respirators, manufactured by St. Paul, Minn.-based 3M Company (and called the 3M Respirator 8612F and 8670F), will be available to the general public without a prescription.

The devices are also certified as N95 filtering facepiece respirators by the National Institute for Occupational Safety and Health (NIOSH). NIOSH certifies respirators for use in occupational settings in accordance with an appropriate respiratory protection program.

An N95 filtering facepiece respirator is a type of face mask that fits tightly over the nose and mouth. It is made of fibrous material that is designed to filter out at least 95 percent of very small airborne particles. The filter and a proper fit determine the effectiveness of the product.

"While the exact nature and concentration of the biological agent or germ may not be known in a public health medical emergency, we believe that minimizing exposure will help reduce risk," said Daniel Schultz, M.D., director, FDA's Center for Devices and Radiological Health. "These respirators are only one part of a combination of approaches that can be used to help reduce the spread of infection between individuals during such events."

Many companies make N95 respirators for workplaces, including health care settings. However, the 3M respirators are the first devices to receive FDA clearance for use by the public during public health medical emergencies to reduce exposure to airborne germs.

Under Occupational Safety and Health Administration and other occupational health regulations, respirators used in the workplace must be individually selected for each worker and tested to ensure a proper fit. This kind of fit testing is not generally employed outside the workplace now and would probably not be feasible during a public health medical emergency.

FDA is requiring those who want to market respirators for use during public health medical emergencies to assure that they are certified by NIOSH to provide adequate filtration without hampering people's ability to breathe. In addition, companies must conduct fit assessment testing, conduct biocompatibility testing to reduce the chance for allergic skin reaction, and provide instructions that will enable wearers to achieve a protective fit and use the devices properly.

3M evaluated fit characteristics in healthy adults to determine that a user could achieve a protective fit following the instructions on the label. They measured how many airborne test particles were able to get inside the respirator through small leaks between the edges of the respirator and the wearer's face. While individual results varied, all participants tested achieved some reduction in exposure to airborne test particles.

The 3M respirators are sized for adults and may not form a proper fit on children. Anything that comes between the respirator and the face, such as facial hair, may interfere with its fit. Persons with pre-existing heart or lung disease or other health conditions may have difficulty breathing through a respirator. The devices are for single use. Wearers should not wash, disinfect, reuse or share their respirator with others. The respirators should be discarded after use.

FDA will soon issue a guidance document outlining its regulatory approach to this new type of device.

Inhaling particles is just one route of exposure to disease-causing organisms. Others include touching contaminated surfaces and coming into close contact with those who have infectious diseases. A total approach to personal protection includes hand hygiene, cough etiquette and other protection practices such as avoiding crowded settings.

Survey Reveals Gap in Public’s Awareness of Nuclear Energy’s Role in Reducing Greenhouse Gases

2007-05-01T06:37:00.000-07:00

Even though nuclear energy is by far the largest clean-air energy source used to generate electricity, fewer than half of Americans strongly associate nuclear energy with clean air, according to a new national survey of 1,000 adults.

The survey shows that only 42 percent of Americans associate nuclear energy “a lot” with clean air. This is the case even though nuclear power plants provide 71 percent of all U.S. electricity that comes from sources that do not emit greenhouse gases or any of the pollutants covered by the Clean Air Act, according to the U.S. Energy Information Administration.

The other clean-air energy sources for electricity are hydroelectric power plants (25 percent), wind power projects (2.3 percent), geothermal projects (1.3 percent) and solar power (one-tenth of one percent).

More than 100 nuclear power plants operating in 31 states provide electricity to one of every five U.S. homes and businesses.

The new telephone survey was conducted March 30-April 1 by Bisconti Research Inc. with GfK and has a margin of error of plus or minus three percentage points. In similar surveys of adults conducted by the same research firms for the Nuclear Energy Institute in May 2005 and March 2006, 55 percent of Americans in both instances strongly associated nuclear energy with clean air.

The new survey also shows that while 57 percent of Americans “have heard or read about” the need for nuclear energy within the past year, only 46 percent have heard or read about the clean-air benefits of nuclear energy. Thirty-nine percent have heard or read about the use of nuclear energy "as a way to fight global warming and climate change."

"Amid the vast amount of media and public policy attention given to global warming concerns over just the past year, there seems to be a disconnect between awareness of the issue and the meaningful measures possible to reduce greenhouse gases," said Scott Peterson, Nuclear Energy Institute vice president.

"For our nation to truly succeed in using the best mix of energy technologies to reduce greenhouse gas emissions, Americans should be better informed about the capabilities that each technology has. This survey shows continued solid support for nuclear energy. The task that lies ahead for our industry is to help the American people better understand that nuclear energy, which they already support, should be an important element of state and national policies to prevent greenhouse gas emissions."

The survey also reveals that people who have heard news during the past year about nuclear energy’s role for clean air or addressing global climate change favor nuclear energy in greater numbers than people who have not. Among those who recall hearing about nuclear energy’s clean-air benefits, 73 percent favor the use of nuclear energy. However, among those who do not recall hearing this, only 49 percent favor the use of nuclear energy.

The survey shows that a plurality of Americans (41 percent) believes climate change "is a serious problem and immediate action is necessary," with another 26 percent of Americans feeling climate change "could be" a serious problem, "and we should take some action now." Only nine percent of those surveyed believe climate change is not a problem and does not require any action.

Another key finding of the survey is that the overwhelming majority of Americans sees nuclear energy as important to our future, but does not recognize how much electricity it supplies today. About 80 percent of those surveyed believe "nuclear energy will be important in meeting the nation’s future electricity needs," with 41 percent feeling nuclear energy will be "very important" and 38 percent feeling it will be "somewhat important."

When asked which sources of electricity are used most today (respondents could name more than one), only 10 percent mention nuclear energy; 32 percent mention natural gas, 31 percent mention coal, 22 percent mention oil, and 16 percent mention hydropower.

When asked which sources of electricity will be used most in the United States 15 years from now, Americans cite solar energy (27 percent) and nuclear energy (24 percent) most. Fourteen percent mention coal-fired power plants, even though coal-fired plants today provide 49 percent of the nation's electricity and are likely to remain the leading source of electricity in the next 15 years.

"People have a similar view of solar and nuclear energy as fuels of the future, but not major sources today," Bisconti Research President Ann Bisconti said. "That’s not new. It's the same view the public has held for nearly a quarter of a century. Misperceptions about our energy supply, coupled with the fact a large segment of the public is not hearing about nuclear energy's clean-air role, result in an underestimation of the magnitude of nuclear energy's contribution right now in addressing concerns about global warming."

The survey shows that 63 percent of Americans favor "the use of nuclear energy as one of the ways to provide electricity in the United States." This is down from the historic high favorability of 70 percent recorded in 2005 and 68 percent favorability last September.

Two-thirds of Americans say that, if a new power plant is needed to supply electricity, it would be acceptable to add a new reactor at the nearest existing nuclear plant site.

You can view the questionnaire used for the survey at:http://www.nei.org/documents/NewsRelease20070423Addendum.doc

Construction Safety Training Resource

2007-04-06T11:01:00.000-07:00

I read a lot of OSHA press releases and have noticed that excavation cave-ins are a major source of injuries, fatalities and OSHA fines. The construction Safety Council offers a free online course that will help you improve excavation safety. The course is called:

EXCAVATION HAZARDS TRAINING FOR THE COMPETENT PERSON
(29 CFR 1926, SUBPART P)

The following is the description provided on the web site:

"At the conclusion of this course, the participant will understand the importance and duties of a competent person performing or supervising excavation work. They will also have the knowledge and skills that are required to perform the duties required of the competent person. A passing score on the final exam will qualify participant to receive an Excavation Competent Person Training Certificate from the Construction Safety Council."

Unscheduled Absenteeism Up in U.S. Workplaces

2007-03-19T06:41:00.000-07:00

A study by CCH® HR MANAGEMENT finds that unscheduled absenteeism is having a significant effect on U.S. businesses. A report on this study opens with the statement:

"With the rate of absenteeism on the rise, U.S. employers are losing ground when it comes to finding effective programs that keep healthy workers on the job, according to the 16th annual CCH Unscheduled Absence Survey by CCH, a leading provider of human resources and employment law information and services and a part of Wolters Kluwer Law & Business (hr.cch.com)."

You can read the complete report at: http://hr.cch.com/press/releases//absenteeism/102506a.asp

The report highlights low employee moral as a significant cause of unscheduled absenteeism. It also discuss "work life" programs that address the needs of employees and which help reduce unscheduled absenteeism.

Why TPM Initiatives Sometimes Fail

2007-02-28T05:34:00.000-08:00

The news is always positive. Lean manufacturing techniques will improve your business. Use Kaizen, Kanban and 5S and your profits will soar anf customers will beat a path to your door. But, it doesn't always work out that way. Sometimes you can spent a lot of money on implementing lean manufacturing and get little or no benefot.

Ans article from the January issue of Reliable Plant Magazine discusses why Total Productive Maintenance sometimes fails.

Metal / Nonmetal Mine Fatalities

2007-02-07T04:47:00.000-08:00

The Louisville Courier Journal reports that although a mine safety law was passed eight months ago, "Federal regulators have been too slow in implementing important provisions of a mine-safety bill that Congress enacted last year, a key House Democrat said yesterday."

A key provision of the bill is that underground mines need to have enough breathing devices to allow miners to reach the surface in an emergency.

Mine fatalities are reported on the Maryland Center for Environmental Training web site.

http://www.mcet.org/mining/mnm/fatalgrams/index.html

Each report is linked to the OSHA web page for the incident. There you can read recommendations for avoiding such accidents.

Lean Newsletter

2007-02-06T18:53:00.000-08:00

The lean learning center publishes a lean newsletter on a somewhat irregular schedule (a lean schedule ). Issue 8 has an article called Conversations From The Road. It is an interview with Gary Smuda who is the Director of Continuous Improvement with Technicolor. In this short, but interesting article, Gary talks about his "lean journey" from its start with a lean mentor.

How to Screw Up a Lean Transition

2007-01-29T20:02:00.000-08:00

All Show: No Go.
Microcosms of Excellence: Negligible Bottom Line Impact.
Solutions Looking for a Problem.
Teams for Teams' Sake.
Unnecessary Complexity.
Foreign Language Studies.
Meaningless Awards & Certifications.
Data Overkill.
These are a few of the more common pitfalls that we see.

One fundamental tenant of Lean Manufacturing is the elimination of waste. Yet, the majority of lean advisors propagate extremely wasteful practices in the transition methodology that they profess.

One of my personal favorites is the "foreign language" mandate. Most Americans can readily relate to the word "waste." Does "muda" really add any value?

After eighteen years, and 100+ plant conversions, we have found only one Japanese word that is truly required in making the transition to lean: "Kanban". Not only is there no easy direct translation into English, but kanban is also a generally accepted universal term. For the others, we find that "level loading," "mixed model production," "opportunity signals," "continuous improvement," etc. work just fine.

Corporate management sent us into one of their large plants. The plant had been losing money and struggling for several years. Yet, the first remark from the plant manager was:

"We really don't need any help. We're already doing lean."

"That's great," we said. "What kind of results have you gotten?"

"We've got 20 certified trainers. Each has been through three full weeks of education" he said.

"That's great" we said. "What kind of results have you gotten?"

"Every employee has had at least eight hours of training" he said. "And, we've got employee teams throughout the company."

"That's great" we said. "What kind of results have you attained?"

Dead silence. The teams had been working on such critical issues as "what radio station should be played over the PA system."

The plant had no overall guiding methodology to implement meaningful change. As a result, after two full years of training expenditures, they had generated absolutely no tangible impact on any of the plants' key measurements.

In that same plant, with the same plant manager, we generated millions in tax free cash through inventory reduction, cut their aggregate lead times by more than 60%, reduced the internal defect rate by 79%, and cut late deliveries by 93%. All within six months of kickoff. Needless to say, overall productivity also increased dramatically.

Another typical implementation approach we call "Solutions looking for a problem." They'll blitz an area. They'll do a 5S pilot. They'll put in some kanbans. They'll form some teams. They'll do a SMED initiative.

This approach generates some nice show places. Microcosms of excellence. All good things to do.
However, when you ask the same question:

"What results have you gotten?" you get a similar response.

"Negligible impact on the bottom line."

It's a scatter-gun approach. The thought process, evidently, is if we fire off enough bullets, eventually we'll hit something!"

Another in-vogue concept is "Six Sigma" or, better yet, "Lean Six Sigma."

The basic idea: combine the power of lean, with the rigors of the statistical quality approach demanded by six sigma.

It's a great marketing concept. But does it really hold any water?

Six Sigma is a well defined process, developed to address complex quality and/or process deviation issues. It is rigorous, and often requires the use of some higher level statistical techniques.

It is NOT, however, an overall operations improvement approach.

And, when you dig a little deeper into the quality gains attained by most self-professed six sigma plants, you'll find that well over 90% of the gains came from simple, completely non-statistical, techniques.

We've visited plants with dozens of Black and Green Belts, and a considerable amount of time and money spent on statistical training at the general operator level as well. Yet we still found piles of inventory, long lead times, and poor customer service (delivery performance).

There is a lot more to "quality," from the customer's perspective, than just having reliable processes!

Transitioning to lean generates dramatic gains in OVERALL process quality. It does this, however, through basic blocking and tackling methods requiring no special statistical training.

1) less inventory means fewer defects and faster discovery (a major component in determining root cause), 2) sequential inspection catches the defect at the very next operation, 3) Stop the line: Fix the problem, and simple "Failsafe" devices make errors difficult or impossible to re-occur, etc.

In a truly lean environment, six sigma is seen as just one more tool in the lean tool kit. It is used where and when appropriate to solve specific, difficult quality or process problems.

We visited another plant that was "already doing lean." When we walked through the facility, it was apparent that it still ran in a completely traditional manor: piles of inventory between operations, no cells, no kanban or other visual means of control, poor delivery performance, etc.

When we asked what they had accomplished in the eighteen months since they'd started working with their lean consultants, they pulled out a three ring binder. In it was an amalgamation of data of every type. They had standard work data, set-up times data, attendance data, job description data, quality data, etc. They had data up the wazoo!

Ask the same question: "What results have you gotten?" Get the same response. Nothing had changed!

We visited another company that wanted to win the Shingo prize. We asked "So, how far along are you in your transition to lean?" They hadn't even begun.

Getting a prize or certification can be a good way of keeping score. It also can be a powerful marketing gambit. It is, however, transitory, and not a very compelling reason to pursue this difficult transition.

To be honest, if serving your customers better than your competition, or assuring the health and well being of the company, or competing against foreign suppliers, etc. isn't compelling enough reason, than you might want to hold off for a while.

We've worked with companies that were already in chapter eleven and fighting for survival. Even with their backs against the wall, and every employee facing possible loss of job, it was difficult to unify the troops to make this transition.

Sustaining the effort needed to become "World Class" demands a higher cause than winning a prize.

In most companies, transitioning to Lean is truly a culture changing process. It requires a new way of managing, with different measurement and reward systems.

It requires an overall company-wide transition process, with clearly defined measurable goals, and well defined responsibilities.

It demands top management's sponsorship and regular on-going administration to assure that the goals are being accomplished. You just can't go out and buy "one of those lean things."

Bottom line? Every company, hopefully, only makes this transition one time. And there are plenty of land mines to be overcome in the process.
Get yourself a good advisor to guide you.

And look out for the snake oil salesmen!

All the best on your lean journey.

About the Author

Jack Harrison is a Senior Partner at the Hands-On Group. Eighteen years lean consulting experience, over 100 successful Lean implementations. Author: "Running Steel Lean," "ERP and Lean," and "Transitioning to Lean." For further information, visit http://www.handsongroup.com

Article Source: Content for Reprint

Kaizen Improves Bottom Line For Drugmaker AstraZeneca

2007-01-26T19:43:00.000-08:00

Bloomberg news reports that "AstraZeneca Plc, the second-largest U.K. drugmaker, is expanding a cost-saving project at a Swedish plant to other sites after the program helped lift profits."

What is the cost-saving project? What they are doing to save money is using Kaizen. Kaizen is a system of using suggestions from those closest to a task, to improve how that task is done. Kaizen typically involves making many small changes, instead of engsaging in large capital projects. The article goes on to to explain:

"The London-based company says techniques inspired by car and truckmakers helped reduce by 60 percent the time it takes to make a drug and lowered per-pill manufacturing costs by 5 percent a year at Soedertaelje, outside Stockholm. Making the changes at other factories means AstraZeneca can increase drug production in the next few years without raising costs."

How did AstraZeneca Plc learn about Kaizen? It wasn't how you'd expect. The didn't hire consultants or have a management team research ways to improve their business. The Bloomberg article describes what happened:

"AstraZeneca, which is second to Glaxo among U.K. drugmakers, says the workers introduced it to Kaizen, a concept of continuous improvement developed by a Toyota executive in the late 1940s, to bring lasting cost reductions."

If you'd like to learn about Kaizen, a free quick start guide is available from the makers of the DuraLabel label printer. Use this link: Kaizen Quick Start Guide.

Employers Must Post Illness/Injury Summaries Beginning Feb. 1, 2007

2007-01-24T21:06:00.000-08:00

OSHA Press Release:

WASHINGTON -- The Occupational Safety and Health Administration today reminded employers that beginning Feb. 1, they must post a summary of the total number of job-related injuries and illnesses that occurred during 2006. Employers are only required to post OSHA Form 300A (summary), not the OSHA 300 log. The summary must be posted from Feb. 1 to April 30, 2007.

"This is an excellent time for employers to review their 300 logs and determine where injuries and illnesses are occurring and determine a strategy to reduce and hopefully eliminate these safety and health hazards," said OSHA Administrator Ed Foulke.

The summary must list the total number of job-related injuries and illnesses that occurred in 2006 and were logged on the OSHA 300 form. Information about the annual average number of employees and total hours worked during the calendar year is also required to assist in calculating incidence rates. Companies with no recordable injuries or illnesses in 2006 must post the form with zeroes on the total line. All summaries must be certified by a company executive.

The form is to be displayed in a common area wherever notices to employees are usually posted. A copy of the summary must be made available to employees who move from worksite to worksite, such as construction employees and employees who do not report to any fixed establishment on a regular basis.

Employers with ten or fewer employees and employers in certain industry groups are normally exempt from federal OSHA injury and illness recordkeeping and posting requirements. A complete list of exempt industries in the retail, services, finance and real estate sectors is posted on the OSHA Web site.

Exempted employers may still be selected by the Department of Labor's Bureau of Labor Statistics to participate in an annual statistical survey. All employers covered by OSHA need to comply with safety and health standards and must report verbally within eight hours to the nearest OSHA office all accidents that result in one or more fatalities or in the hospitalization of three or more employees.

Copies of the OSHA Forms 300 and 300A are available on the OSHA Recordkeeping Web page in either Adobe PDF or Microsoft Excel Spreadsheet format.

Under the Occupational Safety and Health Act of 1970, employers are responsible for providing a safe and healthful workplace for their employees. OSHA's role is to assure the safety and health of America's working men and women by setting and enforcing standards; providing training, outreach, and education; establishing partnerships; and encouraging continual process improvement in workplace safety and health. For more information, visit www.osha.gov.

Improving Kaizen Events

2007-01-24T05:58:00.000-08:00

What is a Kaizen Event?

A Kaizen Event is the application of kaizen techniques, during a short period of time, targeted to make improvements in a specific area or process. The objective is to quickly improve a process. A Kaizen Event is also called a Kaizen Blitz.

Reliable Plant Magazine has an article that looks back at a Kaizen Event at an aerospace company in Indiana to identify lessons that were learned, and how Kaizen Events can be improved. Some of the suggestions include:

Keep the kaizen training to what is actually needed for the event.

Provide the kaizen training at the right time.

Properly scale the scope of the kaizen event.

Measure twice, cut once.

Do not tick off your maintenance support crew.

Pick the right lean tool for the job and use it well.

Watch out for collateral damage.

Go to gemba and stay there the entire week.

This is an excellent article that I recommend reading.

New Game Teaches Children Emergency Preparedness

2007-01-15T22:34:00.000-08:00

While we our interest may be in the area of industrial safety and productivity, most of us have children and we are also concerned about their safety. The following press release from NFPA describes a new emergency preparedness game for children in kindergarden through second grade.

NFPA launches new game to teach children emergency preparedness

January 9, 2007 – The National Fire Protection Association (NFPA) today launched a new Sparky the Fire Dog® game to help children learn about emergency preparedness. The game, “Look and Learn,” is now available free online. It stresses the importance of being prepared for an emergency by teaching children about items that should be included in an emergency supplies kit.

Each year natural disasters disrupt the lives of hundreds of thousands of children and their families. NFPA developed Risk Watch®: Natural Disasters to help children and their families deal with disasters before, during and after the event. Sparky’s® new game is the latest addition to support this effort and is available by visiting NFPA’s Risk Watch® Web site and entering the “Kids Only” section of the site.

"Everyone runs the risk of experiencing a natural disaster and that includes children," said Amy LeBeau, NFPA’s communications manager of public education. "Sparky’s new game is a great way for parents and teachers to educate children about emergency preparedness with a fun interactive lesson."

Players of Sparky’s “Look and Learn” visit six different fun and interactive scenes as they are tasked with assisting Sparky by locating hidden items to complete his emergency supplies kit. During their search for the hidden items, players travel through a Hideaway Island, Campground, Safari, Haunted House, Underwater Adventure and Prehistoric Park to locate things like flashlights, batteries, extra clothing, a whistle, canned food and other items that are often necessities in an emergency. After finding all of the emergency supplies in each section of the game, children will be able to download and print out an emergency supplies checklist that they can use to make their own emergency supplies kit.

Sparky’s "Look and Learn" game provides a fun and safe learning experience for kids and there is no advertising on the kids section of the site. The game is most appropriate for children in kindergarten through second grade, but may be of interest to all ages.

About Sparky®
Sparky the Fire Dog, recognized the world over for his efforts to educate children and adults about fire prevention and life safety, has been the official spokesdog for the NFPA since 1951. Sparky’s award-winning Web site gives kids a safe environment to learn about keeping safe from fire and other hazards while at the same time, having fun. Sparky® and Sparky the Fire Dog® are registered trademarks of NFPA.

About Risk Watch®
Risk Watch® is the first comprehensive injury prevention and disaster preparation program available for use in schools. Developed by NFPA, Risk Watch gives children and their families the skills and knowledge they need to create safer homes and communities. Visit the Risk Watch Web site.

About NFPA
NFPA has been a worldwide leader in providing fire, electrical, building, and life safety to the public since 1896. The mission of the international nonprofit organization is to reduce the worldwide burden of fire and other hazards on the quality of life by providing and advocating consensus codes and standards, research, training, and education.

Keep Safety In Mind As You Put Away Holiday Decorations

2006-12-30T21:29:00.000-08:00

Press Release From NFPA
Keep safety in mind as you put away holiday decorations

December 27, 2006 - Now that the holidays are over, take down your decorations and start the New Year safely, advises the National Fire Protection Association (NFPA) and Underwriters Laboratories Inc. (UL), the not-for-profit product safety testing organization.

According to the NFPA, 20 percent of home fires attributed to Christmas trees occur in January. “Christmas trees can be a significant fuel source if a fire occurs in your home,” said Lorraine Carli, NFPA assistant vice president of communications. “Dried-out trees burn easily and should not be left in a garage or placed against the house. We recommend you remove your tree from the home and dispose of it properly as soon as your Christmas celebration ends.”
“Even well-watered trees dry out after four weeks,” John Drengenberg, consumer affairs manager for UL, explained. “So if your real tree went up right after Thanksgiving, it should be discarded after Christmas and not New Year’s Day.”

Carli and Drengenberg also remind you that Christmas trees aren’t the only holiday decorations that need prompt attention after the holidays.

“Leaving your decorations out for several months or even all year not only aggravates your neighbors,” Carli said, “but it also leaves the wires exposed to rain, snow, cold, the sun, squirrels and birds longer than intended by the safety standards.”

“Many people don’t realize that holiday lights should only be up for a limited time,” Drengenberg continued, “The safety standards are developed anticipating a maximum of 90 days of use per year because these decorations are considered seasonal. If you leave decorations out any longer, the resulting damage could cause an electrical shock or a fire hazard.”
As you unplug and store your lights – whether indoors or outdoors – remember the safety precautions you take now can prevent hazards from occurring next season.

Following is a checklist of safety tips that are not only helpful to stay safe as you take down your holiday decorations, but are useful all year-around:

When using electrical toys or appliances for the first time, carefully read and follow all instructions in the manufacturer's use and care booklet. Make sure electrical toys and appliances have the UL Mark.

Use the gripping area provided on the plugs to unplug electric decorations. Don't pull plugs from electrical outlets by the cord. Yanking or tugging on the cord can damage the cord’s wire and insulation and could lead to an electrical shock or fire.

When putting away electrical light strings, take time to inspect for flaws. Check each light set for broken or cracked sockets, frayed or bare wires and loose connections.·Dispose of worn or broken light sets and replace them. Do not place a faulty set of lights back into the storage box for next year’s use. Store electrical decorations away from children and pets to ensure that cords and wires are not damaged in storage.

Store electrical decorations in a dry place where they can not be damaged by water or dampness.

To keep from having a tangled mess of lights next year, be sure to pack them appropriately. When preparing your holiday lights for storage, you can purchase a holiday light storage reel, or create your own storage systems. For example, wrap the lights around an empty wrapping paper tube or a cardboard square, or wrap each set of lights and put them in individual plastic bags.

For more post-holiday safety tips, to download footage of how quickly a dry Christmas tree incinerates or for photographs related to holiday decoration safety, go to UL's online newsroom or NFPA's fact sheet on Christmas tree fires.

About UL: Underwriters Laboratories Inc. (UL) is an independent, not-for-profit product safety certification organization that has been testing products and writing Standards for Safety for more than 110 years. UL tests more than 19,000 types of products annually, and more then 20 billion UL Marks appear on products each year. Worldwide, UL’s family of companies and its network of service providers include 62 laboratories, and testing and certification facilities. Visit UL's Web site.

About NFPA: NFPA has been a worldwide leader in providing fire, electrical, building, and life safety to the public since 1896. The mission of the international nonprofit organization is to reduce the worldwide burden of fire and other hazards on the quality of life by providing and advocating consensus codes and standards, research, training and education.

Kaizen and the Environment

2006-12-29T05:40:00.000-08:00

The U.S. Environmental Protection Agency has a section ontheir web site called "Lean Manufacturing and the Environment". It provides one of the best introductions to lean manufacturing techniques that I've seen. What I particularly like is that being a government site, it is not tryingto sell services. It just takes a clear, unbiased look at lean manufacturing and lean manufacturing techniques.

These pages are looking at how lean manufacturing applies to the environment. The introductory paragraph states:

"Lean manufacturing is a business model and collection of methods that help eliminate waste while delivering quality products on time and at least cost. EPA is interested in finding ways to maximize the environmental benefits of lean. This website will guide you to information on various aspects of lean manufacturing and its relationship to environmental performance."

However, I recommend clicking on the "What methods are used in lean?" link on the first page. This leads to excellent general information about lean techniques such as Kaizen, 5S, JIT and TPM.

OSHA Compliant Signs

2006-12-19T05:06:00.000-08:00

Safety signs, labels and tags are an important part of your safety communication program. If you are making your own safety signs and labels, it is important to follow the OSHA requirements.

OSHA has published the reqirements for accident prevention signs and tags (1910.145OSHA). It covers the design, application and use of safety signs and symbols. The OSHA specifications cover "all safety signs except those designed for streets, highways, railroads, and marine regulations." They do not apply to bulletin boards or safety posters.

Planning For An Emergency

2006-12-13T05:47:00.000-08:00

The Safe Workplace site, which covers OSHA VPP and safety topics, has just put up a page that covers How A Business Can Plan For An Emergency. This emergency planning article points out the fact that it is difficult to make decisions during an emergency. That's why it is important to have a plan in place before an emergency situation happens. And in some cases you may be required by OSHA to have an emergency plan.

This article is based on an OSHA booklet, and it provides thorough coverage of emergency planning and what should be included in an emergency plan.

Solving Pipe Labeling Problems

2006-12-12T05:07:00.000-08:00

Proper labeling of pipes throughout a facility is an important component of a safety program, as well as for improving productivity. Proper labeling ensures employees, visitors, contractors and emergency response personnel know the contents of a pipe, the hazards it presents, and the direction of flow--allowing them to quickly locate the appropriate shutoff value, if necessary.

However, in some circumstances it can be difficult or impossible to label pipes due to the pipes being dirty, oily, greasey, insulated (but not lagged) or difficult to reach. The new Pipe Grabber pipe marking sleeves solve these problems.

Pipe Grabbers are clear plastic that has been formed in a cylindrical shape that is slit open so they can be "snapped" onto a pipe and will grip the pipe tightly. Labels can be applied to the Pipe Grabber before it is placed on the pipe. The label will adhere to the Pipe Grabber and the Pipe Grabber will have a mechanical grip on the pipe. If needed, Pipe Grabbers can be further secured using plastic ties.

Pipe Grabbers are available in five sizes, fitting pipes with diameters from one inch up to 5.2 inches.

Tips For A Safe and Cost-conscious Christmas Season

2006-12-11T19:10:00.000-08:00

Press Release from ComEd (Chicago)

'Tis the season for festive decorating, and while customers commence with stringing holiday lights ComEd is offering tips for practicing safety and calculating added energy costs.

Indoor and Outdoor Decorating Safety Tips
Decorative Lighting:
-- Only decorate with lights that have a NOEL or U/L testing agency label. Check wires, plugs and sockets for defects. Remember: If in doubt - throw them out.
-- Do not overload outlets and extension cords.
-- Do not run electric cords under carpet, seat cushions or anywhere they may be crushed or broken.
-- Keep electric cords and extension cords out of the reach of children.
-- Turn off all decorative lights when going to bed or leaving the house.

Outdoor Lighting:
-- Be sure decorative lights used outside are approved for outdoor use.
-- Outdoor lights should be hung with insulated staples or hooks rather than nails or tacks.
-- When decorating outdoors, be aware of all power lines. Do not work near overhead power lines or anywhere there is a possibility of contacting an overhead power line, either directly or indirectly with a ladder or other piece of equipment. Do not string lights on outdoor trees that are growing into or near power lines - entire trees may become energized if lights come in contact with a power line.

Christmas Trees:
-- Make sure natural grown trees are fresh. Cut the trunk on a 45-degree angle, about one inch above the original cut, and place it in a sturdy stand. A large tree should be anchored to prevent it from toppling over and possibly catching fire.
-- Be sure to place trees away from fireplaces, radiators, television sets, and other sources of heat that may prematurely dry out the tree and make it more susceptible to fire. Make sure the tree has a sufficient amount of water at all times.
-- When using an artificial tree, make sure it is made of a fire resistant material. Lights should be hung on plastic trees only, never place electric lights on a metallic tree.

Fireplace Safety:
-- Do not burn wrapping paper or boxes in the fireplace. These types of materials ignite quickly and may burn uncontrollably. Wrapping paper also may not always burn completely and can become lodged in the chimney, creating a fire hazard.
-- When cleaning out fireplaces, place ashes in a metal container and store outdoors away from combustibles. Ashes can remain hot for several hours, if not days. Discard ashes only when they have completely cooled.

Fireworks:
-- The coming of the New Year is routinely celebrated with fireworks. Always leave fireworks to the professionals!

How Much Will My Decorative Lighting Cost this Holiday Season?
As holiday celebrants plan for lighting decor at home, ComEd offers the following tips for calculating added energy costs:
1. Determine how many bulbs are on your strands of decorative indoor and outdoor lights. For example: 1,000 total bulbs
2. Check the wattage per bulb - one watt per bulb is common. For example: 1 watt
3. Multiply watts per bulb by number of bulbs. For example: 1 x 1,000 = 1,000
4. Convert to kilowatts (kW) - 1,000 watts equals 1 kilowatt. For example: 1 kW
5. Estimate the number of hours in a month the lights are on. For example: 5 hours per day x 30 days = 150 hours
6. Multiply the total kilowatts by the total number of hours the lights will be on to get the total kilowatt-hours (kWh). For example: 1 kW x 150 hours = 150 kWh
7. Multiply the total kilowatt-hours by the total cost of electricity. For typical ComEd customers, the total cost of energy supply, transmission and distribution of their electricity will be 8.6 cents per kilowatt-hour through the end of the year. For example, 150 kWh x .86 = $12.90

ComEd wishes all its customers a bright, warm and safe holiday season!
Commonwealth Edison Company (ComEd) is a unit of Chicago-based Exelon Corporation, one of the nation's largest electric utilities with approximately 5.2 million customers and more than $15 billion in annual revenues. ComEd provides service to approximately 3.7 million customers across Northern Illinois, or 70 percent of the state's population.

Lean Manufacturing and the Environment

2006-11-14T07:06:00.000-08:00

I came across an article about Kaizen on the EPA web site that is excellent. It provides a good overview of Kaizen and includes some details, such as the "Five Whys", that I've not seen other other overview articles.

Although the article is relating Kaizen to the environment, the principles and approach is the same. This article concludes by saying something similar to this:

"At its core, kaizen represents a process of continuous improvement that creates a sustained focus on eliminating all forms of waste from a targeted process. The resulting continual improvement culture and process is typically very similar to those sought under environmental management systems (EMS), ISO 14001, and pollution prevention programs. An advantage of kaizen is that it involves workers from multiple functions who may have a role in a given process, and strongly encourages them to participate in waste reduction activities."

This article serves as a good introduction to Kaizen, and is also worth a quick read by those who have some experience with Kaizen. You'll find the article at: http://www.epa.gov/lean/thinking/kaizen.htm

Another Trench Related OSHA Fine

2006-11-13T20:38:00.000-08:00

Just last week we reprinted a press release from OSHA about a fine related to trench hazards. Total there was another press release and another fine for the same hazard.

Region 4 News Release
Monday, November 13, 2006

U.S. Labor Department's OSHA Cites Trenching Company for Alleged Safety Hazards at Covington, Ga., Work Site
ATLANTA -- The U.S. Labor Department's Occupational Safety and Health Administration (OSHA) has cited Hall's Trenching and proposed penalties totaling $40,100, for allegedly exposing workers to trenching hazards at a Covington, Ga., work site where water lines were being installed.

"Fortunately, this work site was inspected and hazards abated before a tragedy occurred," said Gei-Thae Breezley, OSHA's Atlanta-East area director. "Too often, employers focus on finishing a job quickly instead of finishing a job safely. Employers must protect employees working in this hazardous industry."

OSHA issued one willful citation to the company, with a proposed penalty of $35,000, for allowing employees to work in a trench over seven feet deep without a cave-in protection system. OSHA issues a willful citation when an employer has shown an intentional disregard of, or plain indifference to, the requirements of the Occupational Safety and Health Act and regulations.

The May 31 inspection also resulted in the company receiving four serious citations, with proposed penalties totaling $5,100, for failing to provide workers with a safe means of entering and exiting the trench; allowing excavated material to accumulate at the edge of the trench wall; and for lacking a safety and health program and employee training. A serious citation is issued when there is substantial probability that death or serious physical harm could result and the employer knew or should have known of the hazard.

OSHA has an alliance with the Georgia Institute of Technology and Georgia businesses across the state to promote trench safety through training and education efforts. The agency also has a separate special emphasis program to reduce trenching hazards through strong enforcement. Cave-ins are a leading cause of worker death and injury in the state.

Hall's Trenching, based in Mansfield, Ga., has 15 working days from receipt of the citations to contest the citations and proposed penalties before the independent Occupational Safety and Health Review Commission. The inspection was conducted by OSHA's Atlanta-East area office located at LaVista Perimeter Office Park, Bldg. 7, Suite 110, Tucker, Ga, phone: (770) 493-6644.

Under the Occupational Safety and Health Act of 1970, employers are responsible for providing a safe and healthful workplace for their employees. OSHA's role is to assure the safety and health of America's working men and women by setting and enforcing standards; providing training, outreach and education; establishing partnerships; and encouraging continual process improvement in workplace safety and health. For more information about trenching safety and other safe work practices, visit www.osha.gov

Trench Cave-In Danger

2006-11-07T08:47:00.000-08:00

In monitoring OSHA press releases I've noticed several types of situations that regularly result in injury or death. One of the leading ones are trench cave-ins. This is such an obvious danger which can easily be addressed that we should not be seeing press releases such a this one.

OSHA Press Release: November 1, 2006

Unguarded 21-foot Deep Trench in Coventry Leads to $41,000 in Fines from U.S. Labor Department's OSHA for Warwick Contractor

PROVIDENCE, R.I. -- A Warwick contractor faces $41,000 in fines from the U.S. Department of Labor's Occupational Safety and Health Administration (OSHA) for allegedly allowing employees to work in a 21-foot deep trench that lacked protection against cave-ins. RICO Corp. was cited for a total of five alleged willful and serious violations of safety standards following a June 8 OSHA inspection of a sewer-installation work site on Hopkins Hill Rd. in Coventry.

"Effective cave-in protection is essential since the walls of a trench can collapse without warning, crushing and burying workers beneath tons of soil and debris before they can react or escape," said Patrick Griffin, OSHA's area director in Rhode Island. "While it's fortunate that no cave-in occurred, safety should never be a matter of luck. The potential for death or serious injury was clear and present."

OSHA also found that the trench lacked a safe means of exit, excavated materials were stored less than two feet away from its edge and an employee working inside the trench lacked a helmet to protect against falling debris. In addition, employees were exposed to injuries from a severely damaged trench box that had been used earlier at the jobsite.

OSHA issued a willful citation with a $35,000 fine for the lack of cave-in protection and four serious citations, carrying $6,000 in fines, for the other items. OSHA defines a willful violation as one committed with an intentional disregard of, or plain indifference to, the requirements of the Occupational Safety and Health Act and regulations. OSHA issues a serious citation when death or serious physical harm is likely to result from a hazard about which the employer knew or should have known.

OSHA standards require that all excavations 5 feet or deeper be protected against collapse. Detailed information on excavation safety, including a trenching "Quick Card," is available for employers and workers on OSHA's Web site at http://www.osha.gov/SLTC/trenchingexcavation/index.html.

The company has 15 business days from receipt of the citations to request and participate in an informal conference with the OSHA area director or to contest the citations before the independent Occupational Safety and Health Review Commission. The investigation was conducted by OSHA's Providence area office at (401) 528-4669.

Under the Occupational Safety and Health Act of 1970, employers are responsible for providing a safe and healthful workplace for their employees. OSHA's role is to assure the safety and health of America's working men and women by setting and enforcing standards; providing training, outreach and education; establishing partnerships; and encouraging continual process improvement in workplace safety and health. For more information, visit www.osha.gov.

Rate of Workplace Injuries and Illnesses Lowest On Record

2006-10-24T07:49:00.000-07:00

OSHA Statement

Statement by U.S. Secretary of Labor Elaine L. Chao On 2005 Workplace Injury and Illness Rates

Overall Rate is Lowest on Record

WASHINGTON -- The rate of workplace injuries and illnesses in the private industry declined in 2005 for the third consecutive year, the Department of Labor's Bureau of Labor Statistics (BLS) reported Thursday, Oct 19. The BLS Workplace Injuries and Illnesses in 2005 report noted that nonfatal workplace injuries and illnesses declined from the previous year—to 4.6 cases per 100 workers in 2005, compared to 4.8 cases in 2004. Secretary of Labor Elaine L. Chao issued the following statement about the report:

"The announcement that workplace injuries and illnesses in 2005 were at an all-time low is more good news for America's workers and reflects the department's effective worker health and safety strategy: 1) compliance assistance; 2) health and safety partnerships with labor, and; 3) targeted, aggressive enforcement against bad actors.

"As encouraging as the report is, there is more to do and the department is working hard to make workplaces even safer and healthier for America's workers."

OSHA Cites New Hampshire Logging Company

2006-10-21T07:54:00.000-07:00

OSHA Region 1 News Release

U.S. Department of Labor's OSHA Cites New Hampshire Logging Company after Worker's Death

CONCORD, N.H. -- A Webster, N.H., logging company faces $44,850 in fines from the U. S. Labor Department's Occupational Safety and Health Administration (OSHA) following the death of a worker who was apparently struck by a tree while working in the woods off Henniker Rd. in Warner. Chuck Rose Logging was cited for 30 alleged willful, serious and other violations of safety and health standards in connection with the July 3 accident.

"By many measures, logging is the most dangerous occupation in the United States," said Rosemarie Ohar, OSHA's area director in New Hampshire. "Preventing accidents and fatalities among loggers requires a combination of effective training, safe work practices, the use of appropriate personal protective equipment and properly maintained tools."

OSHA's inspection found that "danger trees," those that present a hazard to employees working in close proximity to them, were left standing while workers felled nearby trees. OSHA's logging standard requires that such trees be felled and removed by safe means before employees work in their vicinity.

OSHA also determined that employees wore neither leg protection while operating chainsaws nor head protection while felling trees. Other violations cited at the jobsite included lack of employee training, using the domino method to fell trees, improper backcutting, damaged or defective skidders, lack of first-aid training and kits for all workers, an unguarded chipper, failure to assess worksite hazards, excess noise levels and failure to ensure that all loggers were in visual or audible contact while felling trees.

Other hazards identified during the inspection included an unguarded grinder, improper storage of oxygen cylinders, lack of a written hazard communication program and lack of a bloodborne pathogen exposure control program, training and personal protective equipment for first aid providers. The company also was cited for not notifying OSHA of the worker's death within eight hours.

Detailed information about logging safety, including an interactive e-tool is available on OSHA's Web site at: http://www.osha.gov/SLTC/logging/index.html.

OSHA defines a willful violation as one committed with an intentional disregard of, or plain indifference to, the requirements of the Occupational Safety and Health Act and regulations. OSHA issues a serious citation when death or serious physical harm are likely to result from a hazard about which the employer knew or should have known.

The company has 15 business days from receipt of its citations to request and participate in an informal conference with the OSHA area director or to contest the citations before the independent Occupational Safety and Health Review Commission. The investigation was conducted by OSHA's Concord area office, telephone (603) 225-1629.

Under the Occupational Safety and Health Act of 1970, employers are responsible for providing a safe and healthful workplace for their employees. OSHA's role is to assure the safety and health of America's working men and women by setting and enforcing standards; providing training, outreach and education; establishing partnerships; and encouraging continual process improvement in workplace safety and health. For more information, visit www.osha.gov.

NFPA 70E Blog

2006-10-13T07:27:00.000-07:00

While I'm mentioning other blogs I've been hired to maintain, I should mention the NFPA 70E Blog (Arc Flash Safety) at http://www.labelprinters.org/blog/ . NFPA 70E is another area in which no one seems to be compiling current information and news, so that's why this blog was started.

The Label Printers web site is about NFPA 70E labeling, as well as safety labeling in general. However, the blog covers all topics related to NFPA 70E and arc flash safety.

Voluntary Protect Program Blog

2006-10-12T07:53:00.000-07:00

As I surf the web I've not seen any source of current information and news about the OSHA Voluntary Protection Program (VPP). Now there is a place you can go for this information. The Safe Workplace website has a VPP blog that provides news and links about the VPP program, as well as safety related information. The blog is about three months old and has regular posts. (Disclosure - I've been hired to keep the VPP Blog on www.safe-workplace.com up to date.)

Use this link to go to the Safe Workplace VPP Blog.

In addition to the blog, the Safe Workplace web site has an overview of the OSHA Voluntary Protection Program, as well as safety related labeling topics. You'll find a complete navigational system on the blog pages that will take you anywhere you'd like to go in the Safe Workplace web site.

OSHA Makes the Business Case for Safety and Health

2006-10-05T21:28:00.000-07:00

OSHA Press Release: October 5, 2006

OSHA Makes the Business Case for Safety and Health
Agency Unveils New Safety and Health Topics Page

WASHINGTON -- The Occupational Safety and Health Administration (OSHA) today launched a new topics page on its Web site aimed at demonstrating that investment in workplace safety and health makes good business sense.

Making the Business Case for Safety and Health, a new Safety and Health Topic, is a product of several Alliances with OSHA, including the American Industrial Hygiene Association, American Society of Safety Engineers, National Federation of Independent Business, among others. Information on the page focuses on how a comprehensive safety program can help an employer save money and improve business.

"OSHA continues to seek ways to offer services and programs that assist and guide employers on the responsible path to occupational safety and health," said OSHA Administrator Ed Foulke. "This new Safety and Health Topics page serves as a ‘one stop shopping’ tool for information on how investing in workplace safety and health can improve a company’s productivity and bottom line."

The Making the Business Case for Safety and Health Topics page contains direct links to resources showing the costs of workplace injuries and illnesses, economic benefits of workplace safety and health, and how accounting for employee safety in the design stage of a project can result in fewer injuries and illnesses and increased productivity.

The Topics page has a number of additional resources, including success stories, case studies and tools for getting started on improving safety and health in the workplace.

OSHA's Web site includes approximately 200 Safety and Health Topics pages on various workplace issues—from accident investigation to workplace violence. The subjects of the pages include specific workplace hazards, as well as individual industries, and provide assistance for complying with OSHA standards.

Under the Occupational Safety and Health Act of 1970, employers are responsible for providing a safe and healthful workplace for their employees. OSHA’s role is to assure the safety and health of America’s working men and women by setting and enforcing standards; providing training, outreach, and education; establishing partnerships; and encouraging continual process improvement in workplace safety and health. For more information, visit www.osha.gov.

NFPA and ICAA Cite Benefits of Physical Activity, Fire and Fall Safety in Kickoff of Active Aging Week

2006-09-28T02:14:00.000-07:00

The aging of the workforce in the U.S. should be a major concern. My father once told we that he had the mind of a 26 year old in the body of a 70 year old. While our bodies age and become more susceptable to inhury, or minds remain young--leading us to believe we can still physically do the things we used to do.

A press release from the NFPA states:

The National Fire Protection Association (NFPA) has joined forces with the International Council on Active Aging (ICAA) to launch this year's Active Aging Week, September 25 to October 1.

NFPA's Public Education Project Manager Lisa Braxton talks about Active Aging Week:

[The following arew links to available audio clips.]
Who forged the alliance between the ICAA and NFPA?

The NFPA's role in this year's Active Aging Week

What are some examples of the "Remembering When" program?

Why are seniors considered so susceptible?

In celebration of this national health observance, NFPA and ICAA will work with older adults at venues across the U.S. to raise awareness of the benefits of physical activity, fire and fall safety, and proper nutrition.

NFPA will be distributing safety tips from its older adult program, Remembering When™: A Fire and Fall Prevention Program for Older Adults . Remembering When centers on 16 key safety messages - eight fire prevention and eight fall prevention. It is a step-by-step interactive program that includes reproducible handouts, lesson plans, checklists, fact sheets, resource lists, trivia games and brochures.

"Teaming up with ICAA for Active Aging Week gives us another opportunity to make significant improvements in the health and safety of older adults," said Sharon Gamache, executive director of the NFPA Center for High-Risk Outreach, which developed Remembering When. "ICAA launched Active Aging Week to demonstrate that older adults can live life as fully as possible within the six dimensions of wellness (emotional, vocational, physical, spiritual, intellectual, social)," says Colin Milner, CEO, International Council on Active Aging. "We are thrilled to have the NFPA involved in Active Aging Week, as change only occurs when the message gets out there."

Free Active Aging Week events are scheduled throughout the last week of September by seniors organizations, retirement communities, senior centers, health clubs, parks, recreation centers and apartment/condominium complexes that are age-restricted.

The ICAA is the world's largest membership association dedicated to changing the way we age by uniting and working with professionals in the retirement, assisted living, recreation, fitness, rehabilitation and wellness fields. We connect a community of like-minded professionals who share the goals of changing society's perceptions of aging and improving the quality of life for Baby Boomers and older adults within the six dimensions of wellness (emotional, vocational, physical, spiritual, intellectual, social).

NFPA has been a worldwide leader in providing fire, electrical, building, and life safety to the public since 1896. The mission of the international nonprofit organization is to reduce the worldwide burden of fire and other hazards on the quality of life by providing and advocating consensus codes and standards, research, training, and education.

NFPA Contact: Lorraine Carli, Public Affairs Office: +1-617-984-7275

Eight Steps to Shaping Your Safety Culture

2006-08-18T13:26:00.000-07:00

An article by DJ Borbige in the August 11th issue of Industrial Safety & Hygiene News shows the steps involved in changing an organizations culture so as to improve safety.

Lean Manufacturing For High Performance

2006-08-01T10:38:00.000-07:00

An article in the June issue of Maintenance Technology discusses why lean companies stay fat. The article, titled "Lean Manufacturing For High Performance", is also available online.

More than half of U.S. manufacturers have started a lean manufacturing program, but many are not seeing the results they expected. Why? This article points out that these companies are not staying tey course--they do not have a full commitment to lean manufacturing.

The article brings out four important points that are critical to a successful lean manufacturing program:

1) Lean Is A Way Of Life

2) Understanding That Long-Term Success Means Far Reaching Change

3) Getting On (And Staying On) The Scale

4) Avoid The Big Letdown

The article concludes with: "A lean lifestyle has to be a total commitment. Successful practitioners use it to change the entire culture of their companies. They recognize that to stay lean in the long term, they will have to institute strategic and operational changes that go beyond mere manufacturing. They know too, that success involves accurately and consistently measuring the right things and aligning these metrics with common corporate goals."

Harmonization Of Hazard Classification and Labeling

2006-07-10T09:32:00.000-07:00

What is Harmonization Of Hazard Classification and Labeling?

The Globally Harmonized System (GHS) for the classification and labeling of hazardous chemicals is an international effort to have a common and consistent method of labeling hazardous materials. The objective is to have a classification system that allows information such as MSDS created in one location to be clearly understood in another part of the world. GHS is working toward developing consistency throughout the world and thus improve safety.

OSHA has an FAQ page about the Harmonization Of Hazard Classification and Labeling that is a good place to go for more information.

Official Business Link To The U.S. Government

2006-07-07T06:54:00.000-07:00

Are you looking for information from the Federal government? Try the www.business.gov web site. This is the official Federal government web site for communicating with business. It provides the following general topic areas:

Business Laws
Employees
Finances
Government Contracting
International Trade
Other Entrepreneurial Communities
Research And Resources
Taxes
Training
Work Environments

The above link goes to the OSHA page which features information on topics such as:

Do I need to put up an OSHA poster in my workplace? Where can I get a copy?

How can I get help from OSHA to fix hazards in my workplace?

How can I get workplace safety and health training from OSHA?

What Cooperative Programs does OSHA offer?

What is OSHA doing about workplace violence and why?

Who needs to receive the hepatitis B vaccination?

These are just a sampling of the questions on the OSHA page. Each question has a brief answer that, if necessary, includes a phone number you can use to get more information. The www.business.gov web site is an excellent starting point when your business needs information from the Federal government.

Company President Convicted

2006-07-05T12:42:00.000-07:00

Company President Convicted In Employee On-the-Job Deaths

More frequently company executives are being held responsible for safety problems and violations under their leadership. In this case an Arizona jury found the president of Far West Water and Sewer guilty of negligent homicide. In 2001 two workers were killed and another seriously injured after entering a confined space. The company was not following OSHA requirements for confined space entry -- Far West did not train its workers, did not follow required rescue procedures and did not test the air in the tank on the day of the incident.

The OSHA fine in this case was just $31,500, but the state of Arizona brought criminal charges.

An article on LifeLines Online reported: "In the Far West case, after a 22-day trial, the jury found the former president of the company, Brent Weidman, guilty of two counts of negligent homicide and two counts of endangerment in the deaths of 26-year-old James Gamble and 62-year-old Gary Lanser. Previously, the company had been convicted of five felony charges in the same incident and fined $1.77 million for its failure to adhere to OSHA’s Confined Space Standard. As president, Weidman was ultimately responsibility for the company’s safety practices."

I don't know the details of what happened in Arizaona. But when it comes to safety the resposibility starts at the top. Executives need to create a culture of safety. They need to ensure their workplace is safe through their leadership and the policies they require. Plus, it wouldn't hurt to walk around the workplace, talk to employees and see for themselves how their company is run at the lower levels.

Is OSHA The Best Source Of Safety Information

2006-06-24T07:30:00.000-07:00

I ran across this congressional testimony by John Biechman Vice President for Government Affairs for the National Fire Protection Association (NFPA). He points out that because of the time it takes for OSHA regulations and standards to be approved, at times they become effective long after the need is recognized. Mr. Biechman makes the case that standards published by organizations such as the NFPA have more up-to-date standards that reflect current safety needs.

OSHA Announces Targeted Inspection Plan for 2006

2006-06-16T08:32:00.000-07:00

Here is an important press release from OSHA.

OSHA Trade News release
U.S. Department of Labor
OSHA, Office of Communications

OSHA Announces Targeted Inspection Plan for 2006
Agency targets about 4,250 high-hazard worksite

WASHINGTON -- The Occupational Safety and Health Administration announced today that its 2006 site-specific targeting (SST) plan will focus on approximately 4,250 high-hazard worksites in its primary list for unannounced comprehensive inspections over the coming year.

"Our targeted inspection program maximizes the effectiveness of our inspection resources to those workplaces with the highest safety and health hazards," said OSHA Administrator Edwin G. Foulke, Jr. "This program gives us the opportunity to focus our enforcement efforts where it will have the most benefit for workers and employers."

Over the past eight years, OSHA has used a site-specific targeting inspection program based on injury and illness data. This year's program (SST-06) stems from the agency's Data Initiative for 2005, which surveyed approximately 80,000 employers to attain their injury and illness numbers for 2004.

This year's program will initially cover about 4,250 individual worksites on the primary list that reported 12 or more injuries or illnesses resulting in days away from work, restricted work activity, or job transfer for every 100 full-time workers (known as the DART rate). The primary list will also include sites based on a "Days Away from Work Injury and Illness" (DAFWII) rate of 9 or higher (9 or more cases that involve days away from work per 100 full-time employees). Employers not on the primary list who reported DART rates of between 7.0 and 12.0, or DAFWII rates of between 5.0 and 9.0, will be placed on a secondary list for possible inspection. The national incident DART rate in 2004 for private industry was 2.5, while the national incident DAFWII rate was 1.4.

OSHA will again inspect nursing homes and personal care facilities, but only the highest 50% rated establishments will be included on the Primary List. Inspections will focus primarily on ergonomic hazards relating to resident handling; exposure to blood and other potentially infectious materials; exposure to tuberculosis; and slips, trips, and falls.

The agency will also randomly select and inspect about 175 workplaces (with 75 or more employees) across the nation that reported low injury and illness rates for the purpose of reviewing the actual degree of compliance with OSHA requirements. These establishments are selected from those industries with above the national incident DART and DAFWII rates.

Finally, the agency will include on the primary list some establishments that did not respond to the 2005 data survey.

Employers are responsible for providing a safe and healthful workplace for their employees. OSHA's role is to assure the safety and health of America's workers by setting and enforcing standards; providing training, outreach, and education; establishing partnerships; and encouraging continual process improvement in workplace safety and health. For more information, visit www.osha.gov.

Young Workers Health and Safety

2006-02-01T15:51:00.000-08:00

I've had several posting on older worker health and safety and though it appropriate to provide some information on young worker health and safety.

The California Resource Network for Young Worker Health and Safety has created a web site dedicated to this topic. It has information for teens, parents, teachers and coucelors. It also provides information for employers and youth employment specialists. It provides information on key California child labor and health and safety laws, training tips, and other steps employers can take.

Although directed specifically at residents of California, much of the information is useful anywhere. Plus there is a resource page providing links to resources in other states, as well as national and in Canada.

Safety and An Aging Workforce

2006-01-10T13:17:00.000-08:00

The American Society of Safety Engineers has just published at page titled:

"Integrating Employee Safety & Fitness: A Model for Meeting NIOSH's Steps to a Healthier U.S. Workforce Challenge" -- By Fred S. Drennan, James D. Ramsay and David Richey

This paper is available as a PDF document on their web site (use the above link).

The point of the paper is that an aging and out-of-shape workforce is becoming the driving force behind increasing worker's compensation and healthcare costs. To keep these costs under control, employers need to be looking at ways to help employees get more exorise and live a healthier lifestyle.

Creating Custom 5S Posters

2005-12-08T09:30:00.000-08:00

5s is a system for improving quality, productivity, employee job satisfaction, customer satisfaction and profits, and at the same time reducing waste, through systematic cleaning and organizing. It was originally developed by Toyota after World War II as a part of their lean manufacturing system. It is called "5s" because it involves five steps, each of which is named using a Japanese word that starts with the letter "s".

One of the more difficult parts of implementing a 5s system is changing employee habits. It is human nature to prefer what is familiar and comfortable. Learning a new way of doing things can be difficult, even when everyone involved has good intentions.

A good tool to help employees change their habits are 5s posters, signs and banners. They can be used to remind employees about new procedures and standards, as well as reminding them about the overall purpose of 5s and the benefits that 5s will bring. The best way to use posters, signs and banners is to make them using text and graphics that relate specifically to your organization; your 5s plan; and to each work location. This can be done using a machine called a poster printer.

A poster printer is a wide format printer that connects to your PC and can be used just like any other printer--except this printer has a poster-size output. Varitronics is one of the better known manufacturers of poster printers. With a poster printer you can design whatever posters, signs and banners you need on your PC and then quickly print them. You get information and graphics that are specific for your company, and you don't need to wait while an outside vendor prints and ships your posters. A poster printer, such as the Varitronics machines, is so fast and economical that you print posters that may only be used for a couple of days.

Arc Flash Safety

2005-11-22T10:53:00.000-08:00

There are 5 to 10 arc flash explosions every day in the U.S. and approximately 2,000 workers are injured or killed by arc flash explosions annually--yet I had a very difficult time finding information about arc flash hazards on the web.

An arc flash explosion happens when electric power short circuits. This can be caused by equipment malfunction or even by dirt or other foreign material getting into a switch or brbeaker. The result is a sudden explosive "flash" with temperatures exceeding 10,000 degrees. Providing workers with the proper protection, as well as properly labeling arc flash hazards are very important safety practices.

The Wire Markers web site lists a variety of good arc flash resources. They range from magazine articles to technical papers published by the government or professional associations. A few require payment of a fee to access, but most are free.

Modify Workplace Safety for An Older Labor Force

2005-11-10T05:20:00.000-08:00

The American Society of Safety Engineers has just issued a report on the topic of workplace safety for older workers.

The baby boom generation is aging and approaching retirement age, and there is not a sufficient number of younger workers to fill the positions baby boomers will vacate. This means employers will be retaining older workers longer. Although older workers have high productivity and better safety records that younger workers, they do have different needs than the young. The report points out that changes such as the following will improve older worker health and safety:

Improve illumination, add color contrast.
Eliminate heavy lifts, elevated work from ladders and long reaches.
Design work floors and platforms with smooth and solid decking while still allowing some cushioning.
Reduce static standing time.
Remove clutter from control panels and computer screens and use large video displays.
Reduce noise levels.

These, and other suggestions on the ASSE list, not only improve safety for older workers, they improve health and safety for all workers. Use the link above to read the complete press release from the ASSE.

Free Quality Tools

2005-11-03T17:40:00.000-08:00

A web site created by Penn State University Quality and Manufacturing Management graduate students offers free downloading of tools for performing quality and quality management related calculations. Each tool performs a specific function or calculation, so you only need to download the tools that do the calculations you need.

Free Quality Tools Downloads

Most of the tools require Microsoft Excel or Access, but some, such as the Six Sigma Calculator (shown to the right), are stand-alone applications that run on any Windows computer.

This site also has a page that provides independent research documents that provide references and instructions on a variety quality-related topics such as:

Benchmarking
Deming Prize
Basic 7 Tools
Five S's
Learning Curves
Management by Fact
American Customer Satisfaction Index
Total Quality Human Resource Management (TQHRM)
Green Design

And many other subjects... Over 70 documents are available and may be freely downloaded.

Reducing Musculoskeletal Disorder

2005-10-31T03:25:00.000-08:00

When there is a mismatch between the physical requirements of the job and the physical capacity of the worker, there is a potential for a musculoskeletal disorder problem. Ergonomics is the science of preventing these problems by fitting workplace conditions and job demands to the capabilities of workers.

Musculoskeletal disorders (MSDs) have a variety of causes. These include repitition of the same motion throughout the workday, or working in an awkward position, or having to use more than normal force to perform a task, or a combination of these. The level of risk depends on how long a someone is exposed to these harmful conditions, how frequently they are exposed, and the level of exposure.

In addition, other factors can increase the risk of musculoskeletal disorder. For example, tasks that result in fatigue, or existing MSD symptoms and injuries can result in increased risks. The factors that are most likley to contribute to an MDs are:

* Awkward postures
* Repetitive motions
* Forceful exertions
* Pressure points (e.g., local contact stress)
* Vibration

Employorers need to be aware of these within their facility and take steps to reduce employee exposure to these.

Musculoskeletal disorders are among the most prevalent medical problems in the U.S., affecting 7% of the population. They account for 14% of physician visits and 19% of hospital stays. 62% of persons with MSD report some degree of limitation on activity compared with 14% in the population at large.

Often MSDs can be prevented by simple and inexpensive changes in the workplace. Adjusting the height of working surfaces, varying tasks for workers and encouraging short rest breaks can reduce risks. Reducing the size of items workers must lift or providing lifting equipment also may aid workers. Specially designed equipment, such as curved knives for poultry processors, may help.

An excellent online Introduction to Ergonomics course is offered FREE by the Oregon OSHA.

Communication Is Important For Safety

2005-10-17T05:12:00.000-07:00

Having an effective hazard communication program is important both for employee safety, and for meeting OSHA rules. The following is basesd on OSHA's Hazard Communication guidelines (from OR-OSHA 440-3343(5/01).

Here's a checklist to help ensure you have an effective hazard communication system in place:

[] Have you compiled a list of hazardous substances that are used in your workplace?

[] Is there a written hazard communication program dealing with Material Safety Data Sheets (MSDSs), labeling and employee training?

[] Is someone specifically responsible for MSDSs, container labeling and employee training?

[] Is each container for a hazardous substance (including vats, bottles, storage tanks and drums) labeled to identify the product it contains and to provide a hazard warning that communicates the specific health and physical hazards of that product?

[] Is there an MSDS readily available for each hazardous substance used?

[] Do you inform other employers, vendors and contractors whose employees share a work area with your employees, where hazardous substances are used?

[] Do you have an employee training program for hazardous substances? Does this program include:

--- An explaination of what an MSDS is, and how to obtain and use one?

--- An explaination of "right to know?"

--- The contents of the MSDS for each hazardous substance or class of substances?

--- Information informing employees where they can review your written hazard communication program, and where hazardous substances are located in work areas?

--- Information explaining the physical and health hazards of substances in the work area, how to detect their presence, and the specific protective measures to be used.

--- Hazard communication program details including the labeling system and MSDS used in your facility?

--- How employees will be informed about hazards involved in non-routine tasks and the hazards of unlabeled pipes?

Stay Flexible

2005-10-07T05:04:00.000-07:00

I’ve just returned from Russia with a new addition to my management toolbox – a plastic drinking straw with a flexible section near one end. Anyone involved with international business should carry one of these straws in their briefcase. It serves as an excellent reminder of a personal attitude that is essential for international business—stay flexible.

Stay flexible: you’ll be able to take advantage of opportunities you never realized might exist.

Stay flexible: when things are moving slowly use the extra time to build personal relationships. Take the time to be interested in people, not for what you can get from them, but for who they are.

Stay flexible: those with whom you are working may have significantly different priorities. Be open to alternative solutions to problems and obstacles.

Stay flexible: there will be problems. Things will not go as planned. Planes will be delayed. Connections missed. Supplies lost. And materials delivered late. Be willing and prepared to adjust how you do things so as to accommodate the unexpected.

Stay flexible...

Project Management - Labor, Material and Equipment Utilization

2005-06-04T20:04:00.000-07:00

A common situation includes "users" whose needs are not deterministic and the arrival of materials that meet those needs occurring at random intervals. What is the impact on the smooth flow of work? How can bottlenecks and queues be minimized?

Let's look at a construction example in which a crane delivers a load at random intervals. Bunching will occur if loads are delivered faster than they can be used. Shortage will develop when the delivery rate is less than they rate at which loads can be used. While the average delivery rate may be optimal, temporary resource shortages and excesses will negatively effect project productivity.

Waiting Time With Random Arrivals

The best usage of labor, material and equipment can be calculated for various scenarios. The point of this article is note that mathematical tools are available to help us optimize the use of labor, material and equipment. Let's look at an example of determining the cost of waiting time when materials arrive at random intervals.

For this example an average of five trucks with project materials per hour arrive at random intervals. Each load must be inspected and inspection requires ten minutes. The cost of waiting time is $45 per hour.

Using the formula: w = a/2x²(I-a/x)

in which w is the average waiting time, a is the average inspection rate, and x is the deterministic service rate.

This gives us an average waiting time of 0.4 hour at a cost of (45)(0.4)(5) = $90 per hour.

If the inspection rate can be increased to ten loads per hour by using two inspectors, the expected waiting time for any one load become 0.05 hour. This has a cost of (45)(0.05)(5) = $11.25 per hour.

If the cost of an inspector is less than $78.75 per hour then two inspectors should be used.

Portable Firefox

2005-05-23T22:10:00.000-07:00

It's the time of year for me to do some traveling, and I need to travel light. That means no lap top. So how does one stay in touch with email and what's happening on the internet without a computer?

With a memory stick and Portable Firefox.

Portable Firefox is a special version of Firefox designed to be completely self-contained on any media that allows read/write access--and in particular memory sticks. Just find an Internet Cafe, plug your memory stick into any Windows computer, run Portable Firefox, and continue browsing where you left off. All your bookmarks, history, all your settings are stored on the memory stick, ready to be used wherever you are.

Portable Firefox can be downloaded free from:

http://johnhaller.com/jh/mozilla/portable_firefox/

Project Evaluation & Documentation

2005-05-12T16:30:00.000-07:00

When your project is completed, there is still one last phase: evaluation and documentation. In this phrase you create a written report documenting what happened, how well goals were met, and the reasons for variations from the original plan in the final outcome.

Going through the process of writing a report helps you to improve your performance on the next project. It causes you to think through what happened and identify problems and victories that might not have otherwise come to mind. In addition, by putting your evaluation in writing, others in your department or company will benefit from your experience.

You should already have a copy of your initial planning materials, including your goals, task lists, Gantt charts and schedules. Now is the time to evaluate what actually happened vs. what was planned. As you are doing this put a particular focus on communication, as communication is a key to project success. Was there effective communication between team members? What communication problems or roadblocks were encountered? Also evaluate communication with people outside the project team. For example, who did you ask for advice or help, and was the response useful?

Look at how well the project goals were met. Were all of the goals met? Which goals were not achieved and why not? Were some goals modified? Were some goals exceeded? Were additional goals added and how did this affect the project?

What happened that was unexpected? What technical problems were encountered? How did the project team deal with technical problems? Was the team able to overcome all of the technical problems?

Did you seek help from outside the project team? In what areas did you need help? Was the assistance you received useful?

Were there any budget issues? How were they addressed?

Were there any staffing problems? Were there any personal/relationship/cultural problems in the project team?

And finally, conclude your report with the advice you would give to someone taking on a similar project.

Controlling Projects

2005-04-29T16:28:00.000-07:00

In the previous phase (project execution) I mentioned that part of the project manager’s job involves solving problems. This is known as “controlling” the project.

No matter how well you have planned the project, you can expect problems. Projects seldom go as planned. You need to identify deviations from the plan, and respond to them, as early as possible in the project. The sooner problems are identified and resolved, the less impact they have on the overall project.

The key to identifying and accommodating changes and problems early is good communication. Stay in touch with your team members. Don’t just ask them, “How are you doing?” and accept “Fine.” as an answer. Use your tools, such as the Gantt Chart and punch lists, to track tasks. Make sure your team knows you are open to bad news as well as good news. You don’t want team members holding back information about problems because they are afraid of how you will respond.

Face challenges and problems as they come up. Don’t ignore them, hoping something will change or the problem will resolve itself. Get the facts, then based on those facts devise a plan to deal with the problem.

Don’t have a plan that is cast in concrete. Be flexible and revise your plan as needed. In particular as you get close to the completion of the project, team enthusiasm may start to drop off, or a particularly difficult task may be blocking progress. Step back, identify exactly what needs to be done, and create a new plan for accomplishing that task.

If you are nearing completion of a project, but it looks like you will miss the schedule, don’t sacrifice quality in order to make the schedule. It is better to meet your quality goals and be late delivering the project. Not meeting the quality goals usually means more problems, and an even greater loss of time in the future.

Project Execution

2005-04-28T05:15:00.000-07:00

Step one in executing a project is to get started on time. If you start late, and have planned accurately, you’ll probably end late.

Most projects start with a kick-off meeting. This helps get your team focused on what they’ll be doing; allows you to set the schedule for future meetings; provides an opportunity to deal with any last minute problems or changes; and helps to develop commitment to the project and the project schedule.

Everyone will now be off working on their project tasks. As project manager you may have project tasks assigned to you. This means your focus will be divided. Your job as project manager is to stay in touch with team members, and track the progress of the project. The project manager has the “big picture” view and needs to identify problems, and resolve them, as early in the project as possible. Although the project manager is “the boss”, they are also a “servant” to the project team—helping to ensure the team members have what they need to complete their tasks on time.

If you, as the project manager, have tasks assigned to you, be sure to get your tasks completed on time. It’s much too easy to give yourself some slack, allowing the completion of your tasks to lag behind schedule because you have supposedly “more important” things to do. If you don’t complete your tasks on time, other members of the team will not be able to complete their tasks on time.

As the project manager make yourself available. Check your email regularly and be available by phone. Require regular status reports from team members, and provide them with status updates. Keep an eye on the details. For example, have team members use punch lists to ensure the components of tasks are completed and nothing is left out. The punch list then forms the core of the status report for each task.

Project Planning

2005-04-27T16:52:00.000-07:00

In this phase of a project each of the goals set in the previous phase are translated into specific tasks. These are the things that need to be accomplished in order for the goal to be accomplished. Unlike a goal, tasks are specific activities that can be scheduled and assigned to specific people.

Task must be:

Clear – A task is an activity that can be described in one or two sentences.

Independently Time Based – Task should be completed within a specified time without relying on, or having to wait for, other tasks to be completed.

Individual – a task can be assigned such that a specific individual (or team leader) is responsible for the task being completed.

Once the tasks are identified start laying out a schedule for accomplishing the tasks. For small projects a calendar may be all that’s needed. Larger projects typically require the use of a Gantt Chart to visually show which tasks are dependent on others and how tasks overlap. Once tasks are laid out in a schedule you can start to assign manpower, equipment and other resources—allowing you to develop a budget and plan for how your resources will be used. You can also establish milestones for measuring the progress of the project and build quality assurance and acceptance points into the schedule.

You should now have a carefully thought-out plan for the project. It includes specific goals, tasks, resource requirements, and milestones. Put this plan in writing and be sure that all team members have a copy.

Project Initiation

2005-04-04T16:25:00.000-07:00

The key questions in this phase are:

1) Why do we want to do this?

2) What do we want to accomplish?

3) How and when will the project be undertaken?

4) Who will be involved?

Let's look at determining what the project goals are. Keep in mind that goals must have certain characteristics. They must:

* Be realistic and achievable
* Be measurable. You don't know when a goal is achieved, if you can not measure it.
* Be time-based. There must be a point in time when the goal should be achieved.
* Be something in which everyone involved has committed to achieving.
* Be such that there can be clearly defined responsibilities.
* Be specific. Nebulous goals can not be measured, nor can anyone be held accountable for accomplishing them.

Start by brainstorming goals. Write down everything that might be a goal for this project. Also think about side effects and unintended benefits that might result from this project. They may lead to project goals you had not previously considered.

Once you have a list of goals, narrow down that list by eliminating those items that are not really goals, or which do not meet the criteria listed above for goals. For example, your list may include items that are intermediate steps towards reaching the final goal. Those should be taken off the list. But keep them in mind as you may wish to use them later as milestones to measure the progress of the project.

When you have a list of clearly defined, measurable, realistic goals, put the list in writing and give everyone involved a copy. Good communication and documentation at the beginning of a project helps keep people focused, motivated, and committed to the project.

Answer all four of the questions at the beginning of this article, and put those answers in writing. You'll end up with a document that defines the major aspects of the project.

A web page with free online tools and forms that can be used in the Project Initiation stage, including a project initiation checklist, is available at:

Project Initiation Tools

Project Management

2005-04-02T13:34:00.000-08:00

Professional, knowledgeable, effective project management is critical to successful completion of projects that will improve your productivity, quality and safety. In my next five articles I'll provide an overview of the five phases of a project. Throughout April I'll take a more detailed look at various aspects of project management.

The following is a brief summary of the five phases of a project:

Initiation - develop the project concept (vision) and benefits; establish the objectives (goals) and the scope of the project; identify the end users; perform a risk analysis; identify a project sponsor; and start to assemble a team.

Planning - break the project into specific tasks and activities; refine the scope of the project; refine the project team; identify resource requirements; identify standards to be used; detail unusual features; specify quality assurance procedures; establish acceptance procedures; and develop an overall schedule (including milestones and deadlines) and budget.

Executing - accomplish the goals of the project.

Controlling - solve problems and take remedial actions; monitor and control changes; monitor schedule and budget and make appropriate adjustments to the schedule, budget, project or expectations.

Closing - deliver completed project and assess its success.

Microsoft Releases Online Malicious Software Remover

2005-04-01T13:52:00.000-08:00

A free online tool from Microsoft checks your computer for malicious software and fixes any problems it finds. For more information and to use this tool, go to:

Malicious Software Remover

Lean Manufacturing Case Studies

2005-03-30T06:06:00.000-08:00

How are other companies implementing lean manufacturing techniques? Are they working? Do they deliver the promised improvements? The following provide links to a variety of articles describing the experiences of both major corporations and smaller local companies when implementing lean manufacturing techniques.

Five case studies covering lean manufacturing and Kaizen:
Lean Manufacturing & Kaizen

Lean manufacturing changes the culture at Hickman:
Citizen-Times Article

Industry Week Magazine - New Level of Lean Manufacturing
What The Future May Hold For Lean Manufacturing

Free Safety Training

2005-03-29T17:08:00.000-08:00

In a previous post I mentioned the importance of safety. Are you looking for safety training? The Oregon OSHA web site offers free online safety classes. I've taken most of these classes, and they are excellent.

Oregon OSHA Online Safety Courses

Ten courses are available online. These include:

Developing a Violence Prevention Program - Seven modules. Introduces you to the seven-step process of developing an effective workplace violence prevention program. Topics include: Initial assessment, written policy development, prevention measures, training, reporting and investigation, post-incident follow-up, and program evaluation.

Ergonomics Awareness - Five modules. Covers the basic principles of ergonomics in the workplace. These include: risk factor identification, basic workstation design options, and hazard control strategies to eliminate or reduce those risks.

Introduction to Personal Protective Equipment (PPE) - Seven modules. Learn about using personal protective equipment to effectively protect workers from exposure to workplace hazards. Covers program management, hazard assessment, and training requirements.

The Hazard Communication Program (HAZCOM) - Five modules. This course introduces the you to HAZCOM program requirements for manufacturers, importers, distributors and employers. It covers topics such as container labeling, MSDS management, training, and other elements of hazard communications.

On-Premises Absenteeism

2005-03-25T06:10:00.000-08:00

On-premises absenteeism is probably more costly than off-premises absenteeism and employee turnover costs combined.

What is on-premises absenteeism?

It's when employees are at work, but are not actually working, or they are accomplishing less than they should be accomplishing.

No, this isn't about "goofing off". Most employees want to do a good job. But, sometimes employers put roadblocks in the way of their employees.

One example involves lighting and furnishings. Problems in these areas often cause strains for people working with computers. For example, poor or incorrect lighting can result in computer operators having eye strain and headaches. Poor or incorrect furniture can result in repeditive stress injuries, sore backs and necks, and other aches and pains. Employees may be taking extra 10-15 minute breaks every hour to relieve unnecessary stress, aches and pains.

Another roadblock is inadequate training. I once worked for a company that, whenever they asked me to do something that involved my learning a new skill, they dropped the project (or hired an outside contractor) as soon as they learned some training was involved. Their policy was that employees needed to learn new skills off the clock. If an employer isn't willing to invest in upgrading employee skills, that employer can expect to pay the added costs of employees continuing to work using old, inefficient methods and skills.

A third common problem area is not having the right tools for the job. In this case the job takes longer to accomplish, the quality may be lower, and the employee may be exposed to a greater risk of injury. In many situations an employee may not know what the right tool is--they'll spend considerable time trying to figure out how to get the job done with the tools they have, and then use whatever tools are handy. Or they may spend a lot of time waiting for help, or just thinking about how to get the job done with the tools they have. If the job isn't done right, then more time will be lost in redoing the work and making corrections.

These are just three points to consider when evaluating on-premises absenteeism. In each of these examples employees are on the job, but they aren't getting the job done. Are you doing anything that prevents your employees from getting the job done?

In this article I've looked at these points just from the productivity view. However, there are safety and health implications to all of them. Improving productivity goes hand-in-hand with improving safety and health.

Shitsuke – The Final Step

2005-03-16T05:29:00.000-08:00

I’ve already discussed shitsuke in the introduction to 5S. So I’ll add just a few concluding words here:

Shitsuke is the Japanese word for discipline. So as to make it an “S” word in English, it is commonly expressed as Self-Discipline.

The purpose of shitsuke is to ensure the first fours S’s continue to be used properly. It means that people do not return to old habits, but continue to work to the standards that have been established. It maintains the improvements made in the first four steps, and looks for ways to continue to improve.

Shitsuke involves continued training, modeling of behavior by management, and regular audits. Training refreshes old skills and introduces new skills, procedures and standards. Modeling means that supervisors and managers continue to support 5S through their behavior—and through their continued implementation of 5S from the boardroom to the restroom. Auditing means using checklists, and inspections, on a regular basis to ensure the standards established under the fourth S are being used and achieved.

This concludes our look at 5S, the foundation of a visual workplace and of a successful lean manufacturing system.

Creating The Visual Workplace

2005-03-15T05:10:00.000-08:00

5S is often referred to as the Five Pillars of a Visual Workplace. So what is a visual workplace?

A visual workplace (also known as Visual Factory Management) is a system for reducing waste, improving productivity, safety, quality, on-time delivery, profits and employee moral by implementing "visual controls."

At work our vision is typically the main way we take in information. Without thinking we see color, shape, location, distance, contrast and brightness. The purpose of a visual workplace is to use this incoming information to eliminate wasted motion. Why is eliminating waste important? Author Hiroyuki Hirano explains that wasteful concepts of how to accomplish something harm a business:

"Many of these concepts and customs are ingrained into every part of the production, clerical, and sales divisions. With such deep roots, they are not easily uprooted and replaced. To use another biological metaphor, these deeply ingrained concepts and customs are like fat that has been finely marbled into every part of the body. Every ounce of this fat is pure waste, and overweight companies are the least likely to win the marathon race for survival into the next century." Quoted from the Five Pillars of the Visual Workplace by Hiroyuki Hirano (page 1).

A visual workplace eliminates waste by eliminating searching, waiting, questions, interruptions, mistakes and injuries. A visual workplace makes work areas user friendly by answering questions; identifying equipment, materials and locations; describing actions and procedures; and providing safety warnings and precaution information. It does this by recognizing the primary importance of vision. It then makes important information available at the point of need and to make it stand out visually.

Establishing a visual workplace involves proper labeling and signage. It involves establishing visual cues, such as color coding, that identify work areas, tools, storage areas and even people. The objective is to create a workplace in which employees have the information they need, understand their role, and contribute in a positive way to the success of your company.

Workers should be able to locate the things they need with a minimum of effort. Storage areas, cabinets, shelves, bins and closets should be clearly identified. Signs should be clear and visible from a greater than the normal distance from which they are typically viewed. Standardized color coding of signs and labels is used to quickly associate storage areas, tools, equipment and supplies with specific tasks, work areas or products.

Another important area is to identify and clearly mark safety hazards. Use signs, labels and color coding to make recognition of a safety hazard fast and simple.

A good analogy to a visual workplace is our system of roads and highways. They have been designed as a visual system. Signs use shape, color, text and pictograms to convey information. Markings on the roadway inform us of passing zones, the edge of the road, bus lanes, one way streets, and upcoming exits. Mile markers, street signs and city limit signs allow us to identify our location. Just as our workplace should, our road systems use a variety of standardized visual methods to communicate the information we need, at the point of need.

Seiketsu - Creating Standards

2005-03-14T19:29:00.000-08:00

Seiketsu is the fourth step in 5S. Seiketsu can be translated as standardize. In this step the methods used in the first three steps are put into standards.

Standards are used to accomplish several objectives:

Standards Prevent Backsliding: One of the most difficult things to accomplish is preventing people from sliding back into old work habits. It's easy to slip back into what you've been doing for years. That's what everyone is familiar with. It feels comfortable. Standards make people aware that they are going back to old work habits, and provide a means for making corrections.

Standards Allow Measurement: Standards are important because they allow you to measure success and variances. With standards you can measure whether goals are being reached, and they give you a means by which results can be quantified. Management will want to know the ROI from implementing 5S, and using standard provide a way to measure performance and determine ROI.

Standards Detect Variances: Standards also provide a way to detect when there is a variance or a problem that needs correcting.

Implementing Seiketsu

Standards apply to such things as labels, signs, markings, color coding (pipes, conduit, containers, gangways, work areas, etc.), procedures, and schedules.

One way to create standards is to watch those who have done particularly well in some area and implement what those employees did as the standard. In creating a standard, carefully study what your best employees are doing, breaking it down into small steps. Then create standards based on the steps in process you've observed.

Don’t implement standards from the top down. Involve employees in creating standards. They are the ones who are closest to the work that needs to be done and are your best source of hands-on experience and knowledge.

Implementing standards also includes training. Be sure all employees are trained, and tested, on the new standards. When designing your standards keep the need for training in mind. It is easy to design a complex system that is difficult to learn. If in your training you find some employees are having difficultly "getting it", don’t be reluctant to change the standards, looking for ways to simplify them without reducing effectiveness.

Visual Workplace

Seiketsu also includes a technique called visual workplace. Our eyesight is the main way we take in information. Having a visual workplace takes this into consideration, using visual methods to convey information. I’ll talk more about the visual workplace tomorrow.

Seiso - Cleaning, Inspection & Preventive Maintenance

2005-03-11T05:56:00.000-08:00

Seiso is the third step of Five S. Seiso is a Japanese word that translates as cleanliness. In English the words “sweep” or “shine” (regular cleaning) are commonly used as appropriate words beginning with the letter “S”.

Who Cleans?

Once you have everything, from each individual work area up to your entire facility, sorted (cleaned up) and set in order (organized), you need to keep it that way. This requires regular cleaning. This is not just a job for a janitorial staff, everyone should be involved in keeping their work area clean—from the mailroom to the executive suite.

Why Clean?

Dust, dirt, stains, spills and debris hide problems, result in safety hazards, cause accidents and can be toxic. For example, an accumulation of dirt can both hide and cause scratches. A spill, even something as innocent as a coffee spill, can directly cause a slipping hazard and the resulting stain can obscure or cause other problems.

What is Cleaning?

Seiso incorporates three categories of cleaning. The first is an overall cleaning of everything. This usually involves everyone as well as a janitorial staff for the facility. The second involves individual workers and their cleaning of the tools, machines and work areas they use. The third level is the detail level. We’re familiar with “detailing” a car—meaning that every nook, crevice and corner is cleaned. This same type of detailed cleaning applies to the workplace.

While they clean everyone should be asking the question, “Why did this get dirty?” Find the root cause and fix the problem. The result will be that less time needs to be spent on cleaning. Ask questions such as:

Is a filter need to reduce air borne dust?

Is there a leak (lubricant leak for example)?

Is clutter causing dirt to accumulate?

Is the movement of materials, or our storage methods, bringing in dirt?

Cleaning everything at a detailed level may at first appear to require a lot of time. But if you find the causes of “dirtiness” and eliminate them, things will stay clean and less effort will be required.

How?

Use a methodical, standardized approach to cleaning. Use checklists to ensure each cleaning task is done. Use labels, signs, diagrams and charts to provide the information needed for proper cleaning, at the point that information is needed. A while cleaning may seem simple at first glance, ensure that proper training is provided. When someone knows the correct way to clean a machine, tool or work area, they can do a better job in less time.

To ensure everything is cleaned, the facility should be divided into small areas, with a specific person in charge of cleaning each area. Each person should have clearly defined responsibilities for cleaning; be trained in the skills needed; and have the proper cleaning tools, supplies and protective equipment (gloves, goggles, face mask, boots, etc.)

Seiso involves more than just cleaning. It also includes inspection. Regular cleaning makes it easy to spot lubricant leaks, equipment misalignment, breakage, missing tools and low levels of supplies. Minor preventive maintenance should be done during the cleaning process. This way problems are identified and fixed when they are small. If these minor problems are not addressed while small, they could lead to equipment failure, unplanned outages or long - unproductive - waits while new supplies are delivered.

Inspection during cleaning should be proactive. For example, lubricant levels and cleanliness should be checked. Filters should be checked and replaced as needed. Drive belts should be inspected. Don’t just clean, but include an inspection checklist as a part of the regular cleaning schedule.

5S Seiton - Neatness Pay Off

2005-03-08T05:49:00.000-08:00

Step two in 5S is seiton. This Japanese word means orderliness or neatness. In English the "S" words typically used are "systematize" or "set in order".

The goal of seiton is to organize, arrange and identify everything in a work area, and facility, so that it can be efficiently retrieved, used and returned to its proper place. This includes everything that is used in the work area, including tools, parts, drawings, instruments and documentation.

Locate and design storage areas based on the function of the item being stored. In other words, the objective isn’t just to store everything neatly in random locations, the objective is to store things in a way and location that makes getting the job done easier.

Each item should have a clearly designated storage location. Storage areas, cabinets and shelves should be properly labeled. For example, outline areas on the floor to identify work areas, movement lanes, storage areas, finished product areas, etc. Put shadows on tool boards, making it easy to quickly see where each tool belongs.

5S is also applicable to offices. For example, provide bookshelves for frequently used manuals, books and catalogs. Label the shelves and books so they are easy to identify and return to their proper place.

Once everything has a storage location it is important to set up a system that makes it easy to return each item to its proper place. This is where good labeling and identification practices are important. The items to be stored, as well as their storage locations, need to be clearly identified and labeled.

Labeling, naming and color coding should be standardized throughout your facility. Labels and signs should be clear, and easy-to-read from the normal distance they are viewed. If labels need to be changed regularly, use repositionable, magnetic-backed or static cling label materials.

(Information about label and sign making equipment. )

Analyze how things are used and based on your analysis establish “put-away” rules. Understanding how, and the frequency at which an item is picked up and used, is the basis of the put-away rule for that item. For example, a tool that is used 60 times per shift needs to have a close storage location that is easy to access. Otherwise the tool will not be put away properly and may be difficult to find the next time it is needed.

Make it easy to match an item with it’s storage location with the minimum amount of effort. Also be sure to make each storage location appropriate for the item. For example, delicate instruments may require storage with foam padding. For some tools you may need to provide appropriate temporary storage areas. For example, a gauge that is used frequently during a portion of a process may require a padded area on which it can be laid between uses.

Keep safety and ergonomics in mind. There should not be any sharp edges or points that can result in injury. Minimize the amount of bending and reaching that is required. Don’t store items in locations that might cause someone to reach out and lose their balance.

I’ve been talking about individual work areas, but seiton also applies to your entire facility. Include the proper signs and labels, that can be read from the appropriate distance, throughout your facility. Pipes, values, instruments, conduit, control panels, doorways, equipment, storage areas, and offices should all be clearly marked and identified.

Free online Pipe Marking Tutorial

Seiri - Step One in Five S

2005-03-07T06:02:00.000-08:00

The Five S program focuses on establishing visual order, organization, cleanliness and standardization. The results you can expect from a Five S program are: improved profitability, efficiency, service and safety.

The first step in a Five S program is seiri. The equivalent English word that starts with the letter “S” is sort. The literal definition of “seiri” is organization. It refers to organizing work areas such that only necessary things are in the work area.

This first step in 5S involves sorting through everything in each work area and keeping only what is necessary. Materials, tools, equipment and supplies that are not frequently used should be moved to a separate, common storage area. Items that are not used should be discarded.

Don't keep things around just because they might be used, someday. If there are obsolete fixtures, molds, jigs, scrap material, waste and other unused items and materials in the work area, get rid of them.

The objective of seiri is to make it easier to find the things you need and to free up additional space in the work area.

During the sorting process you’ll also be cleaning up. This may reveal broken equipment and tools. These should be repaired or replaced as a part of this step in the 5S process. Clean up and repair any oil leaks. Repaint color-coded components, tools and equipment. Clean and paint floors to make it easier to spot dirt, waste materials and dropped parts and tools. Remove old conduit, piping, tubing, mounting brackets and other remnants of equipment and systems that no longer exist.

The end result of step one in 5S is a cleaned up work area that only has the equipment, tools and supplies necessary to get the job done—and everything is in proper working order.

Introduction to 5S

2005-03-05T05:05:00.000-08:00

5S is usually the first step in implementing a lean manufacturing program. So what is 5S?

The acronym "5S" comes from the five Japanese words, seiri, seiton, seiso, seiketsu, and shitsuke. Roughly translated to English, and picking English words that start with the letter "S", these Japanese words mean: Sort, Systematize, Shine, Standardise and Sustain. "5S" is an approach for cleaning up, getting organized and maintaining what has been accomplished. The result is that you’ll have a cleaner, more organized, safer, and more efficient workplace.

We’ll be taking a look at each of the Five S’s, starting with the last one, shitsuke or "sustain". If your 5S program has not been designed to be sustainable from the beginning, you are wasting your time and money going through the first four steps.

A successful implementation of 5S requires three things: commitment, upper management support and performance measurement.

Commitment: A literal translation of the word "shitsuke" would be commitment. Tomo Sugiyama writes in his "The Improvement Book", "’shitsuke’ is a typical teaching and attitude towards any undertaking to inspire pride and adherence to the standards established."

Commitment means that you must be committed to doing all Five S’s, not just three or four of them. You must also be willing to commit the resources necessary to accomplish all Five S’s—which means a commitment of both time and money. In some cases 5S can be implemented with very little expense, in other cases there may be a need for capital improvements to the work areas or facility. You must also be committed to carrying through on the complete Five S program. Getting a 5S program started, and then walking away from it, will not work. Workers will just slide back into the old way of doing things.

Upper Management Support: Without upper management support, the ability to get the funds and time to implement 5S will be limited. Don’t try to implement 5S on a large scale without full senior management support. A possible approach may be to demonstrate to senior management the significant benefits resulting from 5S by starting small. This can be accomplished by implementing 5S and lean manufacturing on a small scale in one facility or for one product line. After the ROI has been demonstrated on a small scale, 5S can be expanded into other areas.

Performance Measurement: Having measurable performance standards allows you to both track the success of your 5S program, and detect problems so they can be fixed before they become serious. If you are not tracking performance, old habits may slowly return and the benefits of 5S will slip away without anyone noticing.

In addition, measurement of performance gives you the hard numbers you’ll need to take to senior management to get their support for an expansion of 5S in to other facilities and product lines.

Let's conclude today's article with a few words about 5S from Hiroyuki Hirano. He is the author of 5S: Five Pillars of the Visual Workplace:

"A company that cannot successfully implement the 5 Ss cannot expect to effectively integrate JIT, re-engineering, or any other large-scale change. Good workplaces develop beginning with the 5S's. Bad workplaces fall apart beginning with the 5 Ss."

Brady GlobalMak - Review

2005-02-25T05:29:00.000-08:00

Before I conclude this month’s discussion about labeling, there is one more machine I should talk about. In it’s features and capabilities this machine is so far ahead of all others that it deserves recognition.

If you need a labeling powerhouse, the Brady Globalmark is the machine for you. It is available in three models:

Monchrome - prints one color on a different color tapes.

Multicolor – prints in one color, multiple spot colors, and full process color on a different color tapes.

Color & Cut – has the color printing features of the Multicolor model, but also includes the ability to cut labels and signs in custom shapes (or make cut vinyl lettering and graphics).

The supplies available for the GlobalMark cover just about every labeling need, except those that require highly specialized materials--such as required for laboratory and aircraft cable labeling.

Indoor/Outdoor Vinyl: The GlobalMark indoor/outdoor vinyl tapes come in nine colrs and widths ranging from ½” to 4 inches. They have an average 5+ year outdoor durability. The may be applied at temperaturesas low as 0 degrees F and will adhere well to pipes, walls, equipment, windows and most other clean dry surfaces.

Polyester tapes are available in eleven colors. These tapes have a low halide content and are designed for labeling stainless steel pipes and surfaces. The ultra-smooth finish of polyester tape means they are excellent for making signs by mounting to them on rigid panels and for labels applied to very smooth surfaces.

A variety of specialized labeling materials are available for the GlobalMark. These include tag stock material, repositionable vinyl tapes (two colors), metallized poyester tape, static cling tape, non-adhesive magnetic backed tape (two colors), reflective tape (two colors), glow-in-the-dark phosphorescent tape, semirigid brushed gold material, cold temperature tapes (two colors), and die-cut RTK labels.

The GlobalMark is a stand-alone desktop machine that includes a full-size keyboad and large LCD screen. On the color versions of the GlobalMark the screen provides a touch-screen interface making designing and printing labels even easier and faster. The GlobalMark can also be connected to your PC, and can print labels, signs, graphics and photographs stored on your computer.

Changing tapes and ribbons is simple. The top of the GlobalMark snaps open providing a large access area. Being a large guy with big hands I appreciate the room and easy access the GlobalMark provides for changing tapes and ribbons. Tape cartridges can easily be inserted and locked into place in the bottom of the machine. Self-contained ribbon cartridges quickly snap into place on the underside of the cover.

The hundreds of built-in templates included with the GlobalMark are a great time saver. The templates cover six common industrial applications: signs, pipe markers, right-to-know labels (NFPA Diamond and Color Bar formats), tags, equipment identification, and warehouse identification. You can also add your own custom templates, meaning a custom label or sign only needs to be designed one time.

When you have a variety of different labeling and sign making jobs, be sure to take a look at the Brady GlobalMark. It has more features and capabilities than you’ll find in any other label and sign printer.

Proper Container Labeling

2005-02-23T05:54:00.000-08:00

Containers holding hazardous chemicals fall into three categories:

Primary Container - this is the original container from the manufacturer. The manufacturer is responsible for the labeling on his container.

Secondary Container - these are smaller containers used to store and use chemicals. These could be plastic jugs, spray bottles, old coffee cans or drums. Secondary containers must be labeled to identify their contents and the labels must include appropriate hazard warnings. The NFPA diamond is often used on labels for secondary containers.

The purpose of labeling secondary containers is so employees, visitors, contactors and outside emergency response personnel can quickly identify the hazard level of the material in the container. This is particularly important for emergency response personnel as they may need to quickly decide how to approach and deal with a container in an emergency situation. For this reason is is important to use a standard system, such as the NFPA diamond, to mark secondary containers.

Portable Container - these are containers used to transfer hazardous chemicals between labeled containers. They are intended only for the immediate use of the employee who performs the transfer. They may not be left unattended and they must be cleaned after each use. Portable containers are not required to have labeling -- however you may wish to label them so that each portable container has only a specific, designated use.

Pipe Markers Improve Safety & Productivity

2005-02-22T05:29:00.000-08:00

Pipe markers are labels used on piping systems to identify the contents of the pipe, the direction of flow, and whether or not the contents are hazardous. Pipe markers are used everywhere from apartment buildings to paper mills.

What is a pipe? The ASME/ANSI code defines a pipe as "conduits for the transport of gases, liquids, semi-liquids or fine particulate dust."

How do pipe markers improve safety and productivity? By putting needed information directly at the point of need. For example, unmarked pipes are particularly dangerous when outside services are responding to an emergency. Proper labeling of pipes saves time by showing employees and contractors exactly where they are in the system--they don't need to spend time looking through drawings and reference materials. They also help prevent operational errors and guide service staff in tracing through systems to identify problems.

There are three pipe marking standards are most commonly used. The ASME/ANSI standard is the most widely used guideline. Although ASME and ANSI are separate organizations, they’ve agreed to publish the same pipe marking standard and to identify that standard as A13.1-1996.

A second standard is the NFPA (National Fire rotection Association) 99C-1996 / CGA (Compressed Gas Association) C-9-1988. This standard has guidelines for marking piping containing compressed gas and are most commonly used for medical gas piping.

The third standard is published by IIAR (International Institute of Ammonia Refrigeration) and is used for marking piping and components used in ammonia systems.

The purpose of the ASME/ANSI standard is defined as to “assist in identification of hazardous materials conveyed in piping systems and their hazards when released into the environment.” This standard recommends the size of the lettering on the label and the length of the background color field for various pipe diameters. It also recommends label locations. The objective is to have markers that are “located so that they are readily visible to plant personnel from the point of normal approach.”

You can find out more about the ASME/ANSI pipe marking standards in this online pipe markling tutorial.

The NFPA/CGA standard specifies the label location and color coding to be used for compressed gas systems. It also recommends that the label identify the gas and the operating pressure of the piping system.

The IIAR labeling guidelines deal with the special requirements of labeling ammonia systems. In addition to specifying size, color and location of labels, the IIAR system incorporates standard abbreviations that identify the physical state of the ammonia, the pressure and the specific location within the ammonia system. For example, “LIQ” identifies the contents of the pipe as being liquid, and “LTS” identifies the location as the “Low Temperature Suction”.

Information about the IIAR pipe marking guidelines.

Brady ID Pal - Review

2005-02-18T06:10:00.000-08:00

Let’s take a step down in size and look at the 1-1/4 pound (including batteries and label tape) Brady ID Pal thermal transfer label printer. This is one of the smallest, lightest industrial label printers available.

The first thing that strikes me is that the ID Pal is promoted as “designed to be carried in a tool box”. That would be convenient, but a problem I’ve experienced with other electrical devices is that sometimes they get turned on accidentally as they are jostled in my toolbox, resulting in the batteries going dead. On the ID Pal the power button is located next to the LCD screen. A raised edge around the LCD screen protects the screen and, combined with the curved shape of the ID Pal, provides protection for the power button. While it is possible for the ID Pal get turned on accidentally, it does not appear this is likely to happen. And, if it should get turned on, the ID Pal will automatically shut off after about five minutes.

Overall Brady has come up with an excellent ergonomic design for the ID Pal. Its curved shape comfortably fits in either hand, and the ABC style keyboard is easy-to-use. For fumble fingered people such as me, it is nice to see in the specifications that it has been dropped tested in a four foot drop onto concrete.

Three types of supplies are available for the ID Pal: nylon cloth, polyester and vinyl tapes. They are available in three widths, 3/8, ½ and 3/4 inch.

The nylon cloth tape is only available in black printing on a white tape. It is intended to be used for labeling wires, cables and for use on highly textured surfaces.

The polyester tape is available with black printing on a white tape or on a clear tape. Polyester tapes are intended for use on smooth, flat surfaces.

The vinyl tape is available with black printing on six different colors of tape. Vinyl labels are for use on wires, cables, textured surfaces and for general labeling.

With a built-in library of common electrical and datacomm symbols, and preset label lengths for printing wire markers, the ID Pal has been designed with computer network, telecommunications, and other electrical installation and maintenance applications in mind. In addition, instrument technicians, laboratory workers, audio/video engineers and other users of small labels will find this machine handy to have around. The only drawback I can see is that it does not print bar codes.

Kroy 5100 Labeler - Review

2005-02-16T04:59:00.000-08:00

Let’s now go from the large Brady PowerMark, to the small Kroy 5100. This handheld labeler is designed with electrical installations in mind, although it can take on standard labels with it up to one inch polyester tapes.

This appears to be a hot machine right now. Although Kroy gives a list price of $399 on their web site, the lowest price I could find on the web was $430, and it was sold out everywhere I looked.

The Kroy k5100 is a Direct Thermal (DT) / Thermal Transfer printer that has a print resolution of 300 dpi. This provides fine detailed printing that is excellent even for small bar codes.

Supplies for the 5100 come in 1/2”, 0.8” and 1 inch tape widths. Supplies include:

Self-Laminating Wire Wraps – wires and cable

Polyolefin Shrink Tubing – wire labels

Polyester Industrial Labels – general labeling

Laminated Labels – provides greater durability

Tamper Evident Labels – label breaks up leaving a residue if someone attempts to remove it

Cast Vinyl – general labeling that conforms well to corners and bends

Die Cut Labels – for terminal blocks and components

The K5100 is a continuation of the K2000 series and it uses the same supplies as the K2000, K2500, K3000 and K4100. Although in the past Kroy has had problems maintaining an adequate inventory of supplies, with the increased number of printers in user’s hands, hopefully they’ll ramp up manufacturing to better meet demand. However, when purchasing the Kroy 5100 it’s a good idea to be purchasing from a dealer who stocks a significant inventory of Kroy supplies instead of relying on Kroy to have supplies available.

Some of the improvements over previous models include auto sizing, increased print speeds, internal battery charger, downloadable fonts and increased on-board memory.

While larger than some of the handhelds from Brady, the K4100 easily fits in your hand. It’s ABC keyboard is well-spaced and easy to use. Tape cartridges fit into the top of the machine and can quickly be changed with one hand. Overall the Kroy K5100 is an excellent value.

It would be handy to have a belt mounted or shoulder carrying case for the K5100. While not available from Kroy, Graphic Products offers a free K5100 carrying case/holster when you purchase a minimum amount of supplies with a K5100. This is a deal worth considering.

Brady PowerMark - Review

2005-02-14T10:20:00.000-08:00

To start our look at specific label printers I've selected the Brady PowerMark. This is a large format, heavy-duty, thermal, color label and sign printer. The PowerMark is a machine designed for the big labeling jobs in a variety of ways.

PowerMark Supplies - The PowerMark has a good range of supplies available.

The most frequently used supply will be indoor/outdoor grade vinyl. The PowerMark vinyl tapes adhere well to pipes, walls, windows--most clean dry surfaces. The conform well to curved, rough and irregular surfaces. PowerMark vinyl labels are resistent to grease, oil and most industrial chemicals. They have an average five year outdoor life and are available in 11 colors, plus clear.

Low halide polyester tape is available in three colors plus clear. This ultra smooth outdoor grade material is used to labeling stainless steel and nickel surfaces. A typically application would be for making signs that use stainless steel sign panels.

Other specialized supplies available for the PowerMark include reflect tapes, glow-in-the-dark tapes and tag stock.

PowerMark ribbons are available in eight monochrome colors, as well as for two color and four color printing.

Tapes and ribbns are available in widths from 4 inches up to 10 inches.

PowerMark Printer

The PowerMark machine has a heavy duty design that is capable of producing a high volume of labels on adaily basis. It's full-size QWERTY keyboard and large, tilting LCD screen make creating labels and signs easy.

Loading ribbons and tapes is simplified by the easy access to the interior of the PowerMark. The entire top and right-side of the machine lift up, providing plenty of room for ribbon cartridges to be easily installed. Rolls of tape can be quickly put into place and threaded through the tape feed slot.

The PowerMark includes a number of built-in applications that include standard signs, hazardous waste labels, and pipe markers. In addition, custom labels can be stored in the PowerMark's memory.

Printing is crisp and clear. It is resistant to scratches and abrasion.

Overall this is an excellent machine for those who need larger labels, or large numbers of labels.

Kaizen Workcells and Taki Time

2005-02-11T05:36:00.000-08:00

Workcells are the foundation of Kaizen and Lean Manufacturing. A workcell is a small, compact arrangement that includes more than a single machine or workstation. It is a self-contained unit for manufacturing a product, or highly similar products or components. The small physical size of a workcell—typically fewer than 15 machines-- facilitates product movement and communication. Workers within a workcell are usually cross-trained so they can work in several areas within the cell.

Typically the machines in a workcell are arranged in a U-shape. It is typically self-contained, having available all of the resources needed to manufacture a product or component. Machines are arranged in the sequence needed for manufacturing the product or component, so the work-in-progress can flow smoothly from machine to machine. Communication within a workcell is simple since every worker has a common mission and is physically close to others in the workcell.

Balancing Work Flow – Takt Time

“Takt” is the German word for the baton used by an orchestra conductor to set the beat, or the speed of the music. Toyota picked up this word and used it in the Toyota Production System (TPS) as a result of German assistance to the Japanese aircraft industry during World War II. In TPS the term Takt Time is the amount of time it takes to finish one unit of production. He is an example that has been greatly simplified:

If your company makes bicycles, then the amount of time it takes to make one bicycle is the Takt time for bicycles.

Let’s say that your factory makes one bicycle every two minutes. That means the Taki time is two minutes.

Each bicycle has one seat. So the workcell that makes seats must produce one seat every two minutes. That workcell also has a Taki time of two minutes.

Each bicycle has two wheels. That means the Taki time for wheels is one minute. The wheel workcell must produce one wheel every minute.

Each wheel has 24 spokes. To match the wheel production rate the spoke workcell must produce 24 spokes per minute, giving a Taki time for spokes of 2.5 seconds.

How is the Taki Time Determined?

Taki time is set by customer demand. If you receive orders for 240 bicycles per day, that gives a Taki time of two minutes per bicycle (240 divided by 8 hours per day means 30 bicycles per hour are needed).

If demand increases to 480 bicyles per day, the Taki time is reduced to one minute per bicycle. This reduction in Taki time flows throughout the bicycle production process such that the Taki time for wheels is now 30 seconds, and the Taki time for spokes is now 1.25 seconds. Of course, your staffing and resources will need to be adjusted to match the new Taki time. The purpose of Taki time is to keep the workcells in balance, based on the need for bicycles. Thus this is a “pull” system. Each workcell produces the quanity that is required by the next workcell in the production process, based on the demand for the final product.

Immediate Results From Kaizen

2005-02-09T13:15:00.000-08:00

A new article available online describes how a Kaizen mindset, and a quick walk through a manufacturing facility, can result in major cost savings. Tom Dossenbach, the author of the article, points out:

"The norm in industry today is to repair the damage or to remove the symptom. That’s what they were doing. The Kaizen way is to get to the cause and remove it, permanently. Putting it another way, we often are satisfied to say: 'If it’s broken, fix it.' In a plant practicing continuous improvement, the question is: 'Why did it break?'"

Purchasing A Label Printer

2005-02-07T10:17:00.000-08:00

If you already have a label printer that needs to be replaced, you probably have a good idea of what you need. You'll be familiar with the types of labels you use, your labeling volume, and your requirements for label printer features. Your decision involves finding the new machine that meets your current requirements.

For those who do not currently own a label printer, you'll need to start by collecting some information. (Online article about purchasing a label printer). First, how are you currently doing your labeling? How well is what you are doing working? What problems have you had with labeling in the past? For example, if you've used labels produced by an inkjet printer, and had the printing smear or wash off, then you'll need to consider a termal transfer printer instead of a dot matrix label printer.

Have your existing labels been durable? Do they stay stuck?

What needs to be labeled that has not been labeled? Under what environmental conditions will the labels be applied? What environmental conditions must the labels survive? Heat, cold, water, chemicals, abrasion, etc. What size labels do you need? Do your labels need to be color coded? If so, do you need just the tape (background) to be in various colors, or does the printing also need to be in various colors? What colors do you need?

These types of questions will help you determine the types of label materials you'll need and the best printing method to use. The greatest limiting factor for most label printers is the type of supplies available. By knowing what you need your labels to do, you can select a machine that has the supplies you'll need.

How many labels do you expect to need to print each day? A light duty machine can typically handle up to 100 labels a day. If you'll need to print more than 500 labels a day, then you'll need a heavy duty machine.

You also need to consider how quickly you need to print labels, and how frequently during the day labels will need to be printed. These are factors to take into consideration when looking at machine print speed, and when considering whether to purchase one or two machines.

In some cases you may not be able to get a single machine that can do everything you need. It is not uncommon to purchase a heavy-duty desktop printer that remains in one location and handles the bulk of the label printing, and a lightweight, specialized, handheld labeler that can be easily carried wherever it is needed in your facility.

Finally, what features do you need your label printer to have? Does it need to be able to print special symbols? Do you need to use it with a computer database? What type fonts do you need? What languages do you need to use? Does it need to be able to draw boxes and frames?

Once you've compiled all this information, start looking at label printers and supplies. Don't be surprised if you find additional criteria you want in your supplies or printer.

Some of the better brands of label printers to look at include: Brady, K-Sun and Kroy.

Label Materials And Adhesives

2005-02-03T08:09:00.000-08:00

Label tapes are available in a variety of colors and widths. Aty first glance it apears we just need to pick the color and width we want, and we're good to go. But there is a lot more to labeling supplies than what meets the eye.

There are hundreds of combinations of "tape" material and adhesive backing. For example there are paper, polyester, cloth and vinyl tapes. There are permanent and removable adhesives. There are adhesives that adhere to rough surfaces and adhesives that stay stuck at low temperatures. Which type of tape and adhesive you choose depends on what needs to be labeled and the environmental conditions the label will need to withstand.

The purpose of this article is to introduce you to some of the more specialized types of label materials. We all know there are labels that work well on file drawers and other clean, dry surfaces. But what happens when you need to put a label on a textured wall or oily pipe? How about labels for laboratory tools that are subject to nitrogen baths, and what about labels you need to see when there is a power failure and the lights go out?

Polyvinyl chloride (PVC), or just "vinyl" label tapes are available in two basic types of vinyl. Calendered and high performance, which is sometimes called "cast vinyl". The difference between them is in how they are manufactured. Calendered vinyls are made by running the vinyl between rollers to flatten it into a sheet. Cast vinyls are made by by a process that is more like pouring paint onto a flat sheet of paper and allowing it to dry into a thin, smooth sheet.

Calendered vinyls cost less to make and lend themselves to large production runs. They are excellent for most labeling applications since most labeling applications involve flat, smooth or gently curving surfaces. The problem with calendered vinyls is that the rolling process builds stress into the vinyl. This stress tends to cause a small amount of shrinkage over time that results in labels that do not adhere well to objects with tight corners, bumps, rough surfaces or troughs.

The process used to make cast vinyl does not result in stress in the vinyl. Thus cast vinyl will remain tightly adhered in corners, over bumps, on rough surfaces and in troughs. This is why it is called a high performance vinyl. The drawback of cast vinyl is that it costs significantly more.

If you need to label oily or greasy pipes, the best option is to use strap-on or wrap-around labels. Instead of using adhesive, these labels are mechanically attached to the pipe. If you have hot pipes, up to 1000 degrees (F), then porcelain enamel strap-on labels are an option.

When it comes to laboratory labeling labels are needed that can withstand both the high temperatures of an autoclave, and extreme low temperatures of a nitrogen bath. Laboratory labels are made from materials such as nylon cloth, polyester, polypropylene and vinyl. Polyester labels are available that can withstand autoclave temperatures up to 260(F) and some nylon cloth labels are suitable for temperatures as low as -320(F). In some cases, such as labeling test tubes, the thickness of the label is important. Standard labels would prevent test tubes from being inserted into test tube racks. Very thin, low profile, vinyl and polyester materials are available that have a minimum impact on the diameter of the test tube. The specific material you select will depend on the temperature range, resistence to solvents, flexibility and label thickness requirements.

Other types of specialty label materials include glow-in-the-dark materials. These labels will glow allowing them to bee seen and read in the dark. Tamper proof materials are available for labeling tools and equipment in a way that leaves evidence if the the label is tampered with. There are repositionable labels that use an adhesive that allows them to be removed and reapplied in another location.

Just as there are many types of label materials, there are also a variety of label adhesives. Thick, "gummy" adhesives are used on labels intended for use on textured surfaces. There are chemical resistant adhesives, low temperature adhesives and even labels that do not have adhesives such as static cling and magnetic-backed label materials.

When purchasing a new label printer it is important to select a printer that can use the types of labeling materials you know you'll need. While some printers have a wide variety of label materials available, while others are more specialized and can use a limited selection of label types.

Communicating With Labels - Print Methods

2005-02-02T16:29:00.000-08:00

There are two types of print methods used by label printers, impact printing and thermal printing.

Impact label printers are usually dot matrix type printers. This type of printer uses a "matrix" of small wires which impact on a ribbon to transfer an image to the label tape. Dot matrix label printers are typically the lowest price in their size range. They print on paper and produce a medium quality image. They are not suitable for printing fine text or images, and dot matrix labels will not stand up to outdoor weather.

Dot matrix labels are typically used for short term applications or for labels that are not subjected to significant handling. Examples would be labeling in-progress work, marking temporary wires and cables, and making shipping labels.

Thermal labels are created using heat to create the image. There are two types of thermal labels: direct thermal and thermal transfer printing.

With direct thermal printing the print head applies heat directly to a paper tape to produce an image. We most commonly see this type of printing in cash register receipts. The paper tape usually has a flimsy, slick feel to it. Direct thermal labels are low cost, however they are not durable and will quickly fade in sunlight or warm locations. They are best used for temporary labeling applications.

Thermal transfer printing heats a ribbon which then transfers the ink to the label tape. Thermaal transfer printing can produce detailed images and very small text. It can print on a variety of materials, including paper and indoor/outdoor grade vinyls. And thermal transfer printing is durable. The cost of thermal transfer labels varies based on the ribbon and label materials used.

A wide variety of materials are available for thermal transfer printing. They range from paper tapes and die-cut paper labels, to outdoor grade vinyl tapes, to specialized materials such as chemical resistant, glow-in-the-dark, and low temperature materials.

In many cases the same printer can be used to make both direct thermal and thermal transfer labels. Both printing methods use the same print head.

Because of its quality, durability, and flexibility, thermal transfer printing is the most popular label printing method for both home and business uses. Direct thermal and dot matrix label printers are generally limited to specialized applications.

Free Kanban Guide

2005-02-01T15:35:00.000-08:00

A free guide to Kanban just became available. It can be ordered online at:

http://www.graphicproducts.com/free-gifts/kanban-guide.php

Communicating With Labels

2005-02-01T09:11:00.000-08:00

This month I'll be discussing a subject that does not get much attention, labeling. Labels are everywhere, but unless they are required by law, we don't pay much attention to them. However, proper labeling improves communication with the result that productivity is improved, safety is improved, and the information employees/visitors need is available at the point of need.

I'll be start by discussing label printer technologies and their applications. That will be followed by a series of posting about labeling materials -- the tapes and die cut materials labels are printed on. For the remainder of the month I'll review a specific machine each day.

Why is good labeling important? Because it puts information at the point of need. Whether it's safety, maintenance, or operating information; directional information or security information; whether the labels are wire markers, bar codes on tools, or vehicle identification labels; good labeling means that whatever information is needed will be available at the point of need. This results in benefits such as eliminating time wasted searching for information, eliminating confusion, and reducing the potential for errors and accidents. This means there is less wasted manpower and material, there is reduced equipment downtime, and productivity increases.

I hope this series helps you improve communications through labeling.

Problems With Six Sigma

2005-01-31T05:37:00.000-08:00

While Six Sigma is a powerful tool, it does have some drawbacks and it is not suitable for every situation.

Six Sigma is a statistics-based measurement and analytical process that is intended to reduce defects to 3.4 per million opportunities. However, not everything in a business can be reduced to numbers. For example, improving customer experience would be very difficult with Six Sigma. It would also be difficult to use in capital goods sales, in which building relationships is important. Six Sigma would typically not be appropriate in marketing, consulting and service organizations in which people skills are valuable. Six Sigma is process focused, it is not customer focused.

There is also the opportunity for the numbers to be fudged in Six Sigma. With a target of 3.4 defects per million opportunities we first have to ask, "What is an opportunity?" We also need to ask, "What is a defect?" For example, a part of the process may be causing defects, but that part of the process is beyond the control of the Six Sigma team. The answer might be to set the definition of "defect" such that it does not include defects resulting from things that can not be controlled. The problem is, the customer still sees these as defects.

Plus there are two Six Sigma calculations - long term and short term. The long-term Six Sigma calculation includes a fudge factor that accounts for changes that occur over time, such as tool wear. However, not all processes change over time.

Another potential problem is that Six Sigma requires significant training. You can not move ahead with Six Sigma without having a staff trained in Six Sigma. Those with the highest level of training are called Six Sigma Black Belts. However, the training does not ensure the ability to apply Six Sigma in a practical way. And the training does not ensure the holder of a Black Belt has successful, practical experience applying Six Sigma. In other words the head knowledge may not translate into doing.

The bottom line is that Six Sigma is a powerful tool. But it is a tool that needs to be used correctly and applied to the right problems.

What Is Six Sigma?

2005-01-28T05:18:00.000-08:00

I've been talking about Japanese lean manufacturing methods such as Kaizem, Kanban and 5S, but what about Six Sigma? What is Six Sigma?

Six Sigma is a method of improving quality that was developed by Motorola in the 1980's. The term "sigma" is used to indicate variation, and Six Sigma is based on identifying and reducing variation. This can be variation in quality, in process time, in inventory levels, or in costs. Six Sigma uses statistical analysis to identify and correct variations.

There are five parts to Six Sigma represented by the acronym DMAIC:

Define (Identify Projects): Six Sigma starts by identifying a suitable project. Not all businesses and projects are suitable for Six Sigma. Since it is based on statistical analysis, the project must include quantifiable parameters.

Measure (Quantify Current Variation): Look at all aspects of the process to be improved, included related and subprocesses, to identify and quantify all variations.

Analyze: Determine the cause of variations.

Improve: Quantifies the effects of the causes of variations, and identify the maximum allowable range of variation. Establish a calibrated system for measuring deviations of the variables. Once variations can be measured, modify the process to reduce variations to within the acceptable range.

Control (Sustain): Standards, proceedures, training and other tools are used to ensure the modified processs remains within the acceptable range of variance.

Lean Manufacturing and Kaizen

2005-01-27T06:02:00.000-08:00

What is Kaizen and how is it related to lean manufacturing?

Kaizen is a way of running a business such that there is continual improvement, and the improvements are sustained throughthe use of standards.

Kaizen is based on the suggestions made by those who best know what needs to be done to improve--your employees. All employees are encouraged to make suggestions on a regularlay basis. It is not unusual to see an average of 20-25 suggestions per year per employee, and for 90% of those to be actionable.

Suggestions need not be for big changes. The idea behind Kaizen is to use a continual stream of suggestions for small changes to make the product and company better every day. Yes, suggestions for big changes are welcome, but the large number of daily small improvements are what make Kaizen so effective.

When using Kaizen it is important that suggestions be acted on immediately--preferably within 24 hours of when the suggestion is submitted. Remember, you want to be improving every day, so that means suggestions need to be acted on every day.

To see how two companies, Fleetwood and Sony, have implemented Kaizen, visit this library of online magazine articles.

Lean Manufacturing - TPS

2005-01-26T18:54:00.000-08:00

This month I've been talking about ways to improve production and lower costs using techniques such as 5S, Kaizen and Kanban. These were all originally part of the Toyota Production System (TPS), which has since become known as "lean manufacturing".

Lean Manufacturing can be defined as: "A systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection." (NIST)

The term "lean manufacturing" has been adopted because TPS methods use less human effort, they lower inventories, use less capital investment, require less floor space, use fewer materials, and fewer manhours are used produce the same or greater amount of product.

Some of the benefits of Lean Manufacturing include:
<> Greater Flexibility
<> Reduced Inventory
<> Reduced Work-in-Process
<> Quicker Identification of Problems
<> Increased Production Capacity
<> Reduced Lead Times
<> Better Quality
<> Improved Safety
<> Higher Profits

The way to see these benefits is through a process of continual improvement. Implementing lean manufacturing is not a one-time event--it continues into the future forever. Tomorrow I'll introduce Kaizen, which is a system of continual improvement.

The Lean Office

2005-01-26T11:35:00.000-08:00

We usually think of applying lean techniques to manufacturing. A good article about the lean office was just placed on the web. It describes what a lean office is and how Kata Engineering implemented lean office.

Communicating With Kanban

2005-01-25T19:05:00.000-08:00

Kanban is another component of Kaizen.

Kanban is a system that improves the flow of materials through a facility, while reducing waste, reducing inventory costs and improving quality. A Kanban is a "card" with information about a component or item used to make a product. Here's how it works:

Let's say you are making left-handed widgets. One of the components is a turnbull. Turnbulls are delivered on pallets, with 100 turnbulls on a pallet. There is a Kanban (card) attached to each pallet. When a pallet is empty, you send the card back to the turnbull assembler. This tells him you need 100 more turnbulls, which he them makes, loads on a pallet and sends to you.

Kanban is a system that is based on demand. Components and products are not made until there is a demand for them, as indicated by a Kanban (card). For this reason it is called a "pull" system, because material is pulled ahead by demand.

Kanban provides a number of benefits. For example, it allows for continual product improvement. Since there is not a large amount of material held in inventory, product upgrades do not result in unuseable, obsolete parts. Kanban also provides a high degree of flexibility, allowing production to vary to meet demand, for example. It reduces inventory costs, removes administrative blockages, and allows production problems to be quickly identified and fixed.

However, Kanban is not a good option in all situations. It provides the greatest benefit when applied to high volume production lines.

Obviously there is more to Kanban than this very simplistic overview. If you'd like more information, a short online introductory Kanban tutorial is available.