This is the principle behind the 5 whys and it applies well to safety. Next time you are investigating an incident at your plant or workplace, get a team together (it works best with more than one person involved in the thought process) and start asking “Why?” Why did the operator get burned? Because he touched a pipe that was hot. This second post in our series explains how workplace safety is often a positive outcome of applying lean manufacturing principles, particularly the 5S Methodology. 5S Methodology is a way of organizing the work area for optimum efficiency. What many manufacturers find is that optimizing workplace efficiency also optimizes safety. “A properly functioning safety committee fulfills several functions,” said Earl Capps, HR and safety manager at Filters Fast, a retail and distribution company in the Charlotte, N.C., metro area. In some quarters, 5S has become 6S, the sixth element being safety (Safe). More rarely it becomes 7S or 8S with the other elements being save or study. Other than a specific stand-alone methodology, 5S is frequently viewed as an element of a broader construct known.

Have you ever heard the poem “For Want of a Nail” by George Herbert?

It goes like this:

For Want of a Nail

For want of a nail the shoe is lost;

For want of a shoe the horse is lost;

For want of a horse the rider is lost;

For want of a rider the battle is lost;

For want of a battle the kingdom is lost;

And all for the want of a horseshoe nail.

—George Herbert

Flipping this poem around we can apply what is known as “The 5 whys”:

Why was the kingdom lost? (First Why)
Because the battle was lost!
Why was the battle lost? (Second Why)
Because the rider was lost!
Why was the rider lost? (Third Why)
Because the horse was lost!
Why was the horse lost? (Fourth Why)
Because the shoe was lost!
Why was the shoe lost? (Fifth Why)
Because the nail was lost!

This is the principle behind the 5 whys and it applies well to safety. Next time you are investigating an incident at your plant or workplace, get a team together (it works best with more than one person involved in the thought process) and start asking “Why?”

Why did the operator get burned?
Because he touched a pipe that was hot
Why did he touch the pipe?
Because he was reaching for a wrench
Why was he reaching for the wrench? Or Why wasn’t the pipe insulated? Or Why wasn’t there a guardrail to protect against the pipe?

You get the picture.

This process was illustrated on www.shmula.com using Jeff Bezos of amazon.com. In this instance, it was an investigation concerning an employee who had crushed his thumb in a conveyor belt. The 5 whys process went like this:

Why did the associate damage his thumb?
Because his thumb got caught in the conveyor.
Why did his thumb get caught in the conveyor?
Because he was chasing his bag, which was on a running conveyor.
Why did he chase his bag?
Because he placed his bag on the conveyor, but it then turned-on by surprise
Why was his bag on the conveyor?
Because he used the conveyor as a table

So, the likely root cause of the associate’s damaged thumb is that he simply needed a table, there wasn’t one around, so he used a conveyor as a table. To eliminate further safety incidences, we need to provide tables at the appropriate stations or provide portable, light tables for the associates to use and also update and a greater focus on safety training.

(Quoted from the shmula webpage which you can view here.)

The number 5 is simply the most common number of whys that is usually needed to get to the root cause. It the above example, there are only 4 whys needed so don’t get stuck on the number 5. If less get you where you need to be than stop there and implement the solution; if more are needed than keep asking “why?” until you get where you need to be.

As an employer, it’s your responsibility to ensure that your employees are safe and healthy at the workplace. Having the right safety program helps you focus on improving workplace safety. A detailed safety program helps you identify – what you’re doing right at the workplace, where you are lacking and what measures you should take to enhance the safety and health of your employees.

The right safety program helps you prevent injuries and accidents in the workplace. The safety program varies from one business to another. For instance, if you run a small business in a low-risk industry, then you may not have a formal safety program. You may listen to employee concerns as they crop up and respond accordingly.

On the other hand, if you run a factory, then you are most likely to have written safety policies, a full-time safety manager, and more.

The key idea here is to create a safety plan that is the right fit for your organization. This means you cannot download a random safety program that you find on the internet and use it for your business. You have to consider the needs of your business and choose the right program that works for your company.

What makes the Right Safety System?

A successful safety program is a key part of your business, like other operations like finance, HR, stock keeping, and more.

All safety systems should have the following:

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• Dedicated safety manager who is responsible for overseeing the entire process
• Key employees who work along with the safety manager to ensure that all policies are being implemented
• Compliance with state and central regulations
• A system that identifies workplace hazards and eliminates it
• Regular and periodic training for employees
• Build a safety culture at work
• Feedback and continuous improvement

The 5 E’s of a Successful Workplace Safety Program

If you don’t have a formal safety program in place yet, you’re in luck. This guide outlines all that you need to get started with the right safety program for your business.

Before you build a new safety framework for your business, you have to understand the 5 E’s of safety. Wondering what these are? Continue reading to find out.

1. Education

Before you implement workplace safety, you need to ensure that all your employees have a clear understanding of what it is all about. You have to start by teaching them safety rules, building awareness on why it’s essential to work safely and teach them about the importance of creating a safety-first culture at work.

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Without the right education, your safety program will not kick-off as expected. Teaching employees about workplace safety gives them the right guidance to implement it.

2. Encouragement

Safety is a two-way process. You cannot expect all your employees to start practicing safety rules at work just because you made them attend a series of lectures on the topic. You need to provide them with the right incentives to follow the rules and regulations.

Make safety a fun and all-inclusive topic. Encourage employees to provide their feedback and opinions on the subject. Make them feel a part of the process and not just on the receiving end.

3. Engineering

This is where you implement your safety policies. You need to build a specific safety program that meets the specific needs of your business. This is often the most difficult part, and if you’re struggling with this step, you can reach out to Totalika, leading industrial and commercial safety experts in India. Our team will help you create a customized safety plan that meets all your requirements.

4. Enforcement

This is a crucial step in ensuring that your safety plan works as planned. It’s not just enough to have the right safety plan. You have to ensure that it’s being enforced. The primary role of this step is to prevent workplace accidents, save lives, and create a hazard-free, productive work environment.

5. Evaluation

Finally, you need to evaluate your safety program periodically to ensure that it works as expected. Periodic evaluation is a must as workplaces are not static. Operations change from time to time, new hazards crop up, and you need to re-engineer your safety policy to address the changing challenges of the business.

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Evaluation ensures that the right safety resources are used and the safety plan continues to be the right fit for your business.

Wrapping Up – Use the 5 E’s to Custom Create the Right Safety Program for your Workplace

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Use this guide to help you build the right safety program. And, if you need any help at any stage, reach out to our efficient and experienced safety consultants, who ensure that your workplace is safe and free from incidents.