wood industry operations

Risk assessment for production processes

Problem

ManufacturingCo. recorded increasing worker safety incidents at its factories, and sought to improve the safety measures at its factories. ManufacturingCo. wanted a user-friendly risk assessment method which could help the operator identify as well as mitigate risks.

Outcomes

3 Custom risk assessment templates created
2000 Employees using template currently

“We have experienced accidents in our plant recently we want to update our risk assessment process.”

Senior Executive

Quick summary

ManufacturingCo. was in the early stages of establishing safety protocols in its factories. When compared with the across industry benchmarks, its Loss Time Accident Frequency (LTAF) score was significantly higher. ManufacturingCo. sought to improve its safety performance by focusing on worker safety through pre-maintenance risk assessment.

Key question of the project was:

Q. How to develop a risk assessment template that is concise and easy-to-use by production workers?

The situation

Safety standards at ManufacturingCo. were not robust enough to alleviate the injuries or fatalities. In order to improve its safety standards, ManufacturingCo. wanted to develop a custom risk assessment template. ManufacturingCo. decided to focus on the risk assessment templates because it helped cross-functional teams identify areas of risk in a machine or within an activity. Additionally, risk assessment templates further pinpoint the measures to be taken to alleviate those risks.

ManufacturingCo. utilized SCG’s on-demand workforce to accelerate the progress on its risk assessment template. This on-demand sprint accelerated rapid progress on the template creation and implementation.

Our approach

Phase 1: Standards Benchmark

The SCG's agile workforce looked at three different widely used occupational health & safety standards, and extracted the relevant safety features from them. These standards provided the three significant steps of risk assessment.

Phase 2: Industrial Benchmark

To determine the best practices in risk assessment, the SCG's agile workforce compared the current standards of ManufacturingCo., against other companies with lower LTAF. This analysis helped optimize the risk categories for the template.

Phase 3: Interviews and Feedback

Further, SCG’s on-demand workforce conducted interviews and an in-depth analysis. The outcome of the activity provided key features and components of the risk assessment template. Then the risk assessment template was user tested in two manufacturing locations. Finally based on the feedback the final version of the risk assessment template was created.

Results

The SCG’s agile workforce developed three different risk assessment templates by considering different scenarios in ManufacturingCo.’s manufacturing process. These templates accelerated the progress of ManufacturingCo. towards identifying, evaluating and mitigating potential risks by 10X.

Usage flow of the risk assessment templates created

The project proceeded well in the agreed timeline and we were well informed of the activities in different phases. Cooperation with participating members worked well and project outcome met our expectations.

Senior Executive

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