Building a Stronger, More Sustainable, Safer Business

A few days ago, I had the opportunity to talk with the owner of a small mechanical contracting business.

He is a fine man with a very difficult, complex task facing him every day. He has all the burdens of the financial, business, and safety sides of the business on his shoulders. He markets, works with the bank and his accountant to pay the people, the bills and the taxes to keep everything going with no one getting hurt. He seems to be doing quite well with this, but it is a difficult scramble.

He also needs to be in conversation with the local Craft Union Halls to ensure a supply of trained mechanics, brick layers, and pipe fitters. He has a base workforce of about 10 people and augments this with people from the Union Hall as the level of the business projects fluctuate. But the Unions are having trouble getting people to train so the supply of trained craft people is limited, and this causes a lot more strain on him and the business.

pay attention to safety at work to enhance prevention

He does residential and commercial work of all varieties and complexity, so the people need to know what they are doing and do it safely. As various jobs come up, he has to send the right craft people, with the right skill levels to staff the jobs. He has a central office, a large storage area, and a truck garage, but the work is all scattered across a wide geographical area, so he is highly dependent on the people doing the jobs well and safely.

Since some of the newer craft people from the Union Halls are not highly skilled, he also has to do specialized training to bring them up to speed. But discipline is lax; some people come to work late, holding up jobs, while others spend their time on their cell phones rather than paying attention to training videos. This is highly frustrating.

With the wide-spread use of cocaine and other drugs, he is also constantly worrying if the people are mentally ready to do their work. He tries to visually assess the people, but it is very hard to judge drug impairment, so this is a constant worry.

His mind is constantly racing.

Are they setting up the work area so it will be safe? If they are going to use a high-lift, are they setting it up properly with the out riggers properly positioned? Are they lifting properly so they do not hurt their backs? Do they have the right glasses, gloves and other protective equipment and are they using them? Are they looking out for each other? The questions race through his mind.

So here is a good man with a vast array of priorities trying to cover and manage it all. I was impressed at how well he actually was doing.

We then talked together about how he manages and leads all this. Mostly, his approach is to tell the people what to do and remind them to work safely. Several times a week he goes out to see the various jobs and check on their safety. But mostly the people work alone or in pairs and self-manage themselves. He hopes they are always working safely but is concerned that too many of the people may be cutting corners. Several years ago, they did have a very serious injury so that is heavy on his mind.

As we talked, it became apparent that he and his 10-person core team had to change their working relationship from one of top-down orders to one with everyone pulling together so the business can really succeed, be sustainable and no one gets hurt. This core group would all share the leadership responsibilities and ensure that everyone was working at the highest level of safety and fulfilling the demands of their particular jobs.

A Half-Day Workshop

We talked together about bringing them all together for a half-day workshop to talk together about doing things differently. We’ll begin to build the trust they need, to share the information about the need to keep the business profitable, to improve customer relations, to work safely, and keep paying good wages. We would draw out good ideas and insights from everyone and build on these to get better. The collective intelligence of the whole group will rise as we work together in this workshop.

safety prevents accidents in the workplace

We decided to use the Cycle of Intelligence tool to hold and guide the workshop conversation. We’ll begin with the question “How can we build a stronger, safer business together?” As we talk together, everyone will get a better view of what is going on and see the whole business as well as the parts and the interaction of the parts.

Trust will build and together they’ll develop a plan to move forward transforming the business and safety to much higher levels of performance. The key parts of the conversation will be written onto a big wall chart as we go so everyone can see it and keep track of what they see and decide they need to do. This chart will be used as their strategic plan and guide going forward.

I have done many workshops using the Cycle of Intelligence, and improvement always emerges as long as the people are willing to talk together, listen and learn. This is going to be a fun project to see develop. I’ll keep you posted.

If you find that your business can relate to this situation, give me a call at 716-622-6467.

Process Safety Management (PSM)…

Why Process Safety Management is needed and everyone needs to be Involved!

Week after week I read of explosions and fires at refineries, chemical plants and dust-producing operations like sawmills and grain elevators. There are usually people hurt or killed. Communities are forced to shelter in place or evacuate. Families suffer great loss. There are always estimates of the loss of money and the difficulty of getting back into production.

These are sad situations that are usually avoidable if the managers and engineers would only do their duty to conduct strong process safety management (PSM) work. PSM does require having trained engineers to do the work. It may require money when a defect is found the needs repair. It is often routine and boring work as in inspecting relief valves, for example. It often is narrowly focused on just the specific process without taking the whole system into mind. This is critical work that responsible managers and engineers need to conduct rigorously. It is a necessary discipline. (Process Safety Management came about as OSHA’s response to prevent a disaster like Bhopal).

everyone should be involved in process safety management

When I read the reports of these disasters, there are often long explanations about things. There was one I read about where the fluctuating liquid levels in distillation columns were unstable and causing the operators continuous problems. The instruments were not showing the full nature of the problem of the rising liquid levels which, one day, got so out of control that the distillation column overflowed, releasing a flammable cloud which ignited and killed a lot of people. The incident investigation discussed all sorts of technical problems which were not addressed since they did not look too serious. But they did not include the whole system.

Nowhere was there any discussion mentioned about what the operators were experiencing each day and struggling to control. It was clear that they had a serious problem, but no one asked them about it. Why do the technical people treat the men and women who operate the facilities as if they did not know anything. These people live with the processes! They have a lot to offer!

When I was the Plant Manager of the big DuPont Belle, West Virginia plant, we brought occupational safety, occupational health, and PSM together as a whole safety system effort where each part helped the other parts. We created the conditions where people felt it was okay to talk openly together about the problems and address them. Where they helped each other. Trust was built so people could be able to do their best. The people came together enabling us all to perform much better.

Our Total Recordable Injury rate dropped by 97% to ~0.3 and our total emissions to the environment dropped by 95% in just 3 years. I look at total emissions to the environment as a key PSM metric since there is less waste from poorly running processes and fewer upsets or failures blowing stuff into the air.

Building trust and interdependence among the people is a very important part of management’s work. It is easy to do this using the Cycle of Intelligence, listening and learning together. Rosa Carrillo has written a fine book about the importance of the Relationship Factor entitled “The Relationship Factor in Safety Leadership.” This is easy to do if we just go into our organizations, share information, listen, and learn together. It would have avoided the disaster I mentioned earlier in this newsletter.

Yet most managers do not get out of their offices, talk with the people sharing information, listening, and learning together. Why is this? Rosa’s work and my work clearly show the great benefits to safety and productivity, yet managers shy away from this.

WHY????

In your own organization, what are you doing to open up and share information? What are you doing to open up a safe space where it is okay for people to talk and share? Are you bringing a diverse group of people together to talk and learn?

Each of us can make a positive difference. Will you?

osha process safety management elements

Doing Safety Right in the Workforce!

So much of our safety efforts are aimed at trying to get the people to do safety right.

Photo Credit: OSHA.gov/Safety

There are lots of good ideas, new techniques, slogans, better equipment, PPE and so on. When I go to an American Society for Safety Professionals Conference, I am awed by the beautiful displays of new and better equipment and supplies. A lot of safety people are trying to improve safety in the workplace. It is hard work, and progress in reducing injuries and incidents is slow.

My Earlier Years

Over my 20+ years in managerial positions, working to improve the performance of organizations, I have found that the way I worked in my early years of pushing, pushing, scolding, blaming, looking for root cause, etc. was not very successful. I did not listen well and did a lot of arguing. I took an approach of trying to take things apart, thinking that if I understood the parts I could fix things. I felt that I had to know everything and fix the problems and the people. But the same problems kept popping up and no one seemed to learn or care. Trying to catch people doing something wrong, sets us up for a lot of arguments and struggles. Many organizations where I worked were not happy places. (And I learned that it didn’t have to be that way – old school management certainly had its flaws!)

Growing Up

However, when I began to realize that almost all people are smart in their own ways, things began to change. As I learned to purposefully go into the workplace, sit down with the working people, and listen to what they had to say, I found that most people are doing things quite well. They wanted to help to make things better. Most people do not want to get hurt or cause a problem. Rather than treating them as if they just did not care, I realized that they had a lot to offer and wanted to contribute. I just had to ask them, listen, and create the conditions where they could be their best. (They had so much information and innovations to offer!)

At first, I found the people frustrated and unhappy that no one had ever listened to them. When I first began to walk among them, there was a lot of fear and little trust. What was I really doing? Was I really trying to engage with them and learn? Was I just trying to find something wrong in a sneaky way? As I kept trying, kept listening and learning to talk with the people, and not at them, things began to shift. Each conversation was a little step, so I had many conversations. When I was the Plant Manager at the DuPont Belle, WV Plant, I did this for 4-5 hours a day for over 7 years. (Yes, I kept long work hours!)

In talking with the people, building trust, and helping them to see that they were an important part of our total success, our performance improved. In the first 4 years, our injury rate dropped by 97%, emissions dropped by 95%, productivity rose by 45% and earnings rose by 300%. We kept getting better. I did not do this by myself, the people, all of us together did this. I found that in all these conversations that the collective intelligence of the whole organization went up and kept going up as we all talked and learned together. We all became partners in building a successful business.

respect and honor others in the workplace

My Consulting Experiences in Safety

Over the last 28 years of consulting with organizations around the world, to help them improve their performance, I have used and taught this approach. I have developed a focused tool for our conversations that helps to make this work focusedeffective and fast. It helps the people to see what they are doing, breaks down barriers, builds trust, enables them to solve complex problems, and make decisions close to their work. In these conversations the collective intelligence of the groups always goes up. All dimensions of their performance improve, often quite quickly. They sustain this work for years by continuing these conversations among themselves. I call this tool the Cycle of Intelligence. It is simple to use, requires no new capital investment and helps the people, all of them from the top down, to sustain and improve progress in their continuous conversations.

Invitation:

If you want to learn more about the Cycle of Intelligence and how this process works, please give me a call at 716-622-6467 or contact me at richard@rnknowlesassociates.com. We can set up a Zoom call if necessary. (Yes, we do “Train the Trainer” sessions.)

Perhaps you have a story you want to share. It is so important to establish your credibility as a manager or supervisor who is committed to improving safety and to respect your people – because worker participation, involvement and enthusiasm is a treasure. Hope to hear from you!

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