Addressing the Needs of a Manually Intensive Work Environment Alex Tomash, CSP Drew Bossen, PT, MBA Wednesday, December 3, 2014 8:30 -10:00 AM
Agenda • Omega Cabinetry and MBCI Background • Our Business • Goals and Challenges • Our Process • Solutions • Considerations During Planning
Born in a Barn 1977 Omega Cabinets was founded by Bob Bertch. 1978-83 Manufactured bath vanities exclusively. 1984 Moved to Peters Drive campus – introduced Omega Custom Kitchens. 1984-89 Sales grew from $3.5 to $18.1 million. 1989 Introduced semi-custom line Dynasty Cabinetry 1989-93 Sales grew from $18.1 to $47.6 million. 1994 Omega Cabinets acquired by Code, Hennessy & Simmons 1995 Omega Cabinets acquires HomeCrest Cabinetry 1997 Omega Cabinets acquired by Butler Capital & grows to be the 7th largest cabinet manufacturer. 1999 Omega Cabinets acquired KitchenCraft Cabinetry of Canada and becomes 4th largest manufacturer of cabinetry in North America. Combined sales of nearly $300 million. 2002 Omega Holdings is acquired by MBCI and Fortune Brands. 2013 MBCI acquires WoodCrafters
A Family of Brands
Locations • Operations in Canada, U.S. and Mexico • Largest Cabinet Manufacture in North America
What We Stand For We've built our reputation as one of the best cabinet makers around by committing ourselves to the four basics: • Quality Construction • Fashionable Products • On-time Delivery • Complete Delivery We utilize Lean Manufacturing Principle • MPS – MasterBrand Production System • Safety/Ergo 1 st Element Assessed
Our Product Omega Custom Products Custom Vanity Custom Island
Our Product Custom Wall Mount Vanity Custom Vanity Custom Shoe Rack
Our Product Custom Hutch w /Lights Custom Draw er Base Custom Corner Bookcase
Our Product Custom Draw er Bases
Omega Today Rough Mill Receiving Dynasty Components Custom Production Offices Assembly Dynasty Finish Opaque Custom Assembly Distribution Finish Finish Center Campus = 420,000 sq.ft. Hourly = 720 Salaried = 120 Western Receiving Fleet Drivers = 27 12
Our Goals • Establishing and Maintaining a “world class” Total Safety Culture • Incident Rate Below 2.0 • 8 Key Safety Actions (KSA) per month • Always Aware Activity Completion 98% 2015 Goals • 10 Ergonomic Assessments/month • 98% of employee observed/coached per month (leading measure) • 2 Ergonomic Related Key Safety Actions (KSAs) per month (leading measure)
Injury Data Recordables 80 69 70 60 50 40 31 30 20 17 15 13 11 11 11 10 0 2007 2008 2009 2010 2011 2012 2013 2014
Injury Data Recordable Rate 6 5.23 5 4 3.3 3 2.57 2.4 2 1.61 1.56 1.52 1.26 1 0 2007 2008 2009 2010 2011 2012 2013 2014
Injury Data Lost Work Days 250 207 193 200 174 150 125 118 100 50 26 24 8 6 0 2007 2008 2009 2010 2011 2012 2013 2014 2014*
Injury Data WC$ Per Hours Worked $0.18 $0.17 $0.16 $0.15 $0.14 $0.14 $0.13 $0.12 $0.12 $0.10 $0.08 $0.08 $0.06 $0.06 $0.04 $0.04 $0.02 $0.02 $- 2007 2008 2009 2010 2011 2012 2013 2014 2014*
Challenges • Do you feel like you don’t know where to start? • How do you prioritize with so many issues? • We can and do build anything. • There are just as many non-standard tasks as normal production tasks. • 130 New Hires in the first 3 quarters. • Aging workforce. • Heavier product. • Manual movement.
Our Process 3 Angle Approach • Post offer pre-placement screen • Early Intervention (Personal Wellness) • Ergonomic Assessment (Risk Assessment)
Pre-Placement Screen • Positions are categorized into one of three levels • Evaluation occurs on site • Temp to hire in most cases, 75% • If the test criteria is not met, the next level of testing will be performed • Limitations are generally identified at this stage • Reasonable accommodations evaluated
Personal Wellness • Emphasis on Early Intervention and reporting • Daily huddle meeting occur and give employees a chance to report issues to their supervisor • Average time gap is 1 week • 103 employee attended personal wellness in first 3 quarters 2014 • Basic triage and assessment of symptoms • Job site evaluation may occur for some cases
Risk Assessments 3 Tier Risk Evaluation Strategy • Level 1: Personal Risk Assessment, Safe Observation Checklist (Basic Tools) • Level 2: EHS Audits, JSA Reviews, Functional Job Assessments (Intermediate Tools), • Level 3: Safety FMEA, Ergonomic Assessments (Advanced Assessment Tools)
Interventional Matrix… Case Management Return to Work Total Systems Evaluation Approach Rehab Services Recordable Event Reactive Ergonomics Employee Triage Discomfort Pro-active Ergonomics & Wellness Pre-work Screens Essential Function Profiles of Jobs
Interventional Matrix… Case Management Get them back Return to Work to work quickly Evaluation Rehab Services Recordable Event Reactive Ergonomics Help them Employee Triage avoid injury Discomfort Pro-active Ergonomics & Wellness Hire the right Pre-work Screens people Essential Function Profiles of Jobs
Interventional Matrix… Case Management Return to Work Evaluation Rehab Services Recordable Reactive Event Approach Reactive Ergonomics Employee Triage Discomfort Pro-active Ergonomics & Wellness Proactive Approach Pre-work Screens Essential Function Profiles of Jobs
Interventional Matrix… Case Management Return to Work Case Evaluation Management Rehab Services Recordable Event Reactive Ergonomics Medical Management Employee Triage Discomfort Pro-active Ergonomics & Wellness Pre-work Screens Essential Function Profiles of Jobs
Interventional Matrix… Case Management Return to Work Evaluation Data Flow Rehab Services Recordable Event Reactive Ergonomics Employee Triage Discomfort Pro-active Ergonomics & Wellness Pre-work Screens Essential Function Profiles of Jobs
Management of the Three R’s… • Requirements • Risk • Restrictions
The Silo In Which We Live…
Human Resources… Roles and Responsibilities • Hiring and Placement • ADAA Compliant Job Descriptions • Post Offer Pre-work Screens HR • Return to Work
ES&H… ES&H Roles and Responsibilities • Safe Work Practices • Injuries and Illnesses • OSHA 300 Logs
Ergonomics… Roles and Responsibilities • Quantify the Risk • Abate the Risk • Education & Training • Safety Ergo
Return to Work… Roles and Responsibilities • Job Matching • Job Modification / ADAA • Work Re-Design • Vocational Training & Placement RTW
Administration… Roles and Responsibilities • Accountability • Compliance • Return on Investment • Profitability Admin
Today’s Reality… ES&H HR Admin Ergo RTW
Function in Alignment… Single Solution Admin HR ES&H Ergo RTW
Requirements… • Lifts • Carries • Push / Pulls • Stoops • Squats • Twists • Bends • Grips • Reach
Requirements…
Requirements… • Lifts • Carries • Push / Pulls • Stoops • Squats • Twists • Bends • Grips • Reach
Risk…
Risk… • Exposure • Strain Index • REBA • WISHA • Push • Pull • Carry
Risk…
Restrictions…
Restrictions…
Restrictions…
Restrictions…
Restrictions…
Return to Assessment Work Process Functional Job Match Job Analysis Ergonomic Who / How Risk Assessment REBA / WISHA Strain Index Solutions Controls
Ergonomic Risk Assessment Atlas Works • REBA • Moore Strain Index • NIOSH Lifting Equation Other Resources • Liberty Mutual Material Handling Tables • Safe Pull Tool – See Form
Risk Assessments • Risk Prioritization Number (RPN): A RPN score is created by completing either a Cause and Effect Matrix (C&E) or a Safety Failure Mode and Effects Analysis (SFMEA) • Evaluation of the potential failure modes and effects from each job task • Multiplier Effect – Severity X Probability X Existing Level of Protection = RPN Number/Score
Failure Modes Effect Analysis FMEA Existing Protection Probability Severity 1. None Required or Basic PPE 1. Injury Not Expected 1. No Injury or First Aid 3. Eng. Controls in Place 3. Low Risk Of Injury 3. Recordable or Restricted Duty 5. Specific Procedure or 5. Medium Risk Of Injury Authorized Training 5. Lost Time < Week 7. High Risk Of Injury 7. Awareness Training or 7. Lost Time > Week Common Knowledge 9. Injury Imminent 9. No Controls Available 9. Serious Event
Failure Modes Effect Analysis FMEA Current State Future State
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