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How do you standardize your work procedures to improve both safety and productivity while, at the same time, getting valuable input from employees on what they think works best?

Lied’s in Sussex, Wisconsin has adopted both “Kaizen” and “Lean” philosophies. They have held 10 weeklong “Kaizen events” where cross-departmental teams of workers have focused on specific projects, determined new and improved processes, and put them into place.

“To date (since mid-December 2004), 56 of our approximately 225 employees have participated in one or more Kaizen events,” Plant Buyer Erin Maurer says.
”Resulting from these 10 events have been more than 150 ‘implements’ or improvements. We estimate that about 75 percent of these implements either directly or indirectly address safety.”

“Kaizen” is a Japanese word meaning “continuous improvement,” and the “Lean” philosophy strives to eliminate all waste in an organization. Among the many specific projects Lied’s employees have undertaken using these principles are: organizing, cleaning, and improving efficiencies in the three work areas of the equipment repair shop; loading balled and burlapped plant material onto trailers; and developing standardized work procedures for hooking a truck to a trailer.

“Our equipment repair shop is still clean, safe, and organized 10 months later,” Maurer notes. “That never would have been the case in the past.” 

Finding That “Best Practice”

Maurer, who notes that Kaizen is “not top-down driven,” says the purpose of developing standardized work procedures “is to find that best practice.” Input is sought from employees throughout the company. A cross-departmental team of several workers from all levels then spends a full week coming up with the best improvements.

“These people are empowered to make change,” Maurer says. “We have had a very good commitment from the top level [of the company], and that makes a huge difference. Our employees are really excited about this.”

Once a new process is adopted, standardized work sheets that include photos and other “visuals” are developed. They are posted on two “storyboards” within the company, plus are maintained on computer and in company trucks. The work sheets are “living, breathing documents” subject to change if a better “best practice” is later found, Maurer says.

The following is Lied’s Standard Work Sheet for Hooking a Truck to a Trailer.  

Standard Work Instructions: Hooking a Truck to a Trailer

1. Back truck to within five feet of trailer.
2. Adjust trailer eye hitch height to accommodate truck.
3. Using a co-worker to guide you, back the truck to the trailer.
4. After pintle of truck is in the eye of trailer:

Crank down eye over pintle.

 Latch pintle down (ensure locking mechanism has engaged).

 Insert pin if applicable.

 Plug in lights.

 Hang safety chains crisscrossed with open hook side facing trailer.

 Raise jack stand and secure.

 Remove chocks from tires and place in tongue basket.

 Sweep trailer deck to remove debris (or can use a blower).

 Do pre-trip check (tires, lights, emergency trailer brake).

 ENSURE THE EMERGENCY TRAILER BRAKE IS CONNECTED.   

11/05

By Barbara Mulhern, PLANET Safety Specialist