Presenters: Karen Mazerolle BN/RN October 2010

1. The IMG’s Safety Story Presenters: Karen Mazerolle BN/RN October 2010

2. IMG’s Goal Change our culture from a production with a safety approach to SAFE PRODUCTION

3. What happened to us? The Safety Issues • We grew faster than the company’s infrastructure. • Contrary to our belief, safety was a secondary priority. • Focus was on hitting production targets! • Trend of accidents increased as the company grew

4. (cont) • New employees (massive rapid hiring) • Limited orientation and training • Poor Maintenance Program • In the absence of a plan the culture defaulted to the assumption (every body knows what to do). • Accidents became epidemic and culturally engrained as part of the dangerous nature of IMG. Tough man (person) culture!

5. How Big Was the Problem? • Accidents were considered as a cost of doing business • Accidents were becoming more serious • Process left completely to Work Safe, lack of ownership • Sense from employees, IMG did not care about safety. • Public perception was very poor. (Chop shop)

6. Workforce Challenges Changing the attitude that “we have done it this way for 20 years” Encouraging the employees to speak up about safety concerns Convincing employees that safety is the #1 concern and it is being addressed by management Motivating employees that change is necessary for improvement Discipline around unsafe acts

7. What became our Focus Addressing Urgent safety concerns to prevent future injuries Safety issues were addressed promptly and employees were given feedback – building employee trust Implementing reliable structure for change ie. monthly inspections, safe work practices, scheduled communication (posters, safety talks) H&S training for all employees including management

8. How did the process flow Management recognized that safety was a concern Partnership with Work Safe NB was developed A Health & Safety Plan was developed using the 5 *22 model H&S Plan was signed by the President Employees were informed of the plan The 5*22 Safety survey was completed by all employees during work hours

9. “Original 8” of the 22 H&S Topics • H&S Policy – Responsibilities & commitment from all levels • H&S Plan – Ownership & accountability • H&S Communication – Increasing employee awareness • Identification of Hazards & Risks – meeting legislated requirements, increased employee awareness of risk, educational tool used during employee orientation • Control of Hazards & Risks – Specific Action Plan , target area • Accident reporting – Employee participation in safety, action taken to prevent future accidents. • H & S Inspections – useful in identifying & controlling hazards • Health and safety educational needs assessment helped develop an inventory of training requirements

10. Safe work Practice Hand Position when Making Anti-Gust Hazard: Dimple punching product without a Guard in Place Control the Hazard: Right Right hand holding the side of the product Left hand holding the piece to be dimple punched

11. Other steps taken Plant rules reviewed with employees via safety talks and posted throughout the plant IMG outsourced an Equipment safety hazards inspections and every machine was inspected Hazards were prioritized & necessary steps taken Employees were kept updated on progress Safety items were priority – a maintenance employee was designated to safety for 6 months

12. 5 FUNDAMENTALS HEALTH & SAFETY TOPICS 1. Health & Safety Policy 2. Health & Safety Plan HEALTH &SAFETY RESPONSIBILITY 3. General Health & Safety Rules 4. Health & Safety Procedures / Practices 5. Legal Obligations 6. Health & Safety Actions 7. Health & Safety Communication MANAGEMENT COMMITMENT 8. Management Support 9. Well-being of Employees 10. Health & Safety Orientation EMPLOYEE INVOLVEMENT 11. Employee Participation 12. Required Safe Practices 13. Identification of Hazards & Risks 14. Control of Hazards & Risks HAZARD & RISK MANAGEMENT 15. Hazard & Risk Reporting 16. Accident Reporting 17. Accident Investigation 18. Accident and Injury Analysis 19. Health & Safety Inspections 20. Health & Safety Educational Needs HEALTH &SAFETY EDUCATION 21. Health & Safety Education Delivery 22. Health & Safety Education Effectiveness

13. We have seen results

14. Imperial Sheet Metal Accident Frequencycompared to other companies in NB in metal industry

15. The First Focus Department • Through the accident analysis the department with the highest number of accidents was identified • Accident reduction teams developed in that department • Meetings held bi-weekly and included management, department employees from all shifts ,maintenance and JHSC • Input encouraged from employees. • Action plan developed and communicated.

16. 2002 Accident analysis • Main focus was on the Register department • Two Hazards were identified within this department • Cuts • soft tissue injuries

17. A glove supplier was consulted Several types of gloves were identified that had high cut protection Glove trials were conducted and employees were encouraged to give feedback The proper gloves were purchased Safe work practices were developed and communicated – Yes employees were required to wear the proper gloves 2003 there was 4 cuts a 80 % decrease

18. Soft Tissue injuries In 2002 Register department had 11 back and 3 shoulder injuries Accident reports were reviewed Employees were encouraged to identify problems and concerns Work Safe ergonomic consultant assisted with the process Observations were done Hazards identified & possible solutions discussed

19. A Soft Tissue training power point was developed and presented to all the employees in the register department • The training was to increase the employees awareness of how the body worked, the causes and how to prevent Soft tissue injuries • With the group working together and communication going out to all employees in the department hazards were identified and solutions were agreed upon

20. What was accomplished through team work • The weights that were carried to the work stations was identified as a hazard and employees are encouraged to reduce the amount of product carried (this is in the employees control) • Tables with wheels were purchased to transfer the material

21. Tilt bins were made that reduced the need to bend to the floorCost $1500.00 each($12000.00 total)

22. Roller system was installed to reduce push/pull force required on storage bins

23. Positive Results 2003 In the Register department 2 back & 1 shoulder injury 79% decrease

24. Accident reduction was seen through out the facility 43% accident reductionseen throughout the plant in 2003 Further reduction of 25% seen throughout the plant in 2004

25. Employee Wellness/accident reduction • Soft tissue injuries was identified as the number one injury • Outside company observed our production process and developed a stretching exercise program • Exercise program initiated throughout the production area • Comfort surveys were completed & repeated 6 weeks after the program started - a decrease in employee discomfort seen in several areas

26. Problem Solution Outcome Increased costs associated with soft tissue injuries of the upper extremity and low back Implementation of a job specific exercise program Cost of program development and implementation: Total $595.00 August 1,2003 to May 31,2004 Total of 24 Soft tissue injuries Lost time days = 211 August 1,2004 to May 31,2005 Total of 14 Soft tissue injuries Lost time days = 54 Reduction of soft tissue injuries =42% Lost time days due to soft tissue injuries reduced by 74% Positive outcomes

27. Exercise Program Cost of program development and presentation = $595.00 Cost of 15 minute presentation and demonstration to production employees = $4000.00 ( wages and lost production) Total lost $4595.00

28. Lost time days difference from 2004 & 2005 =156 daysWhat would be paid out by Work Safe 85% loss of earnings for 156 days = $13056.Not taking into consideration Medical cost or lost productioncost savings is $8461.What does it mean to the employee that did not get InjuredPriceless

29. Safety is priority when developing new processes

30. Vibration & risk of soft tissue identified

31. Equipment purchased to reduce Hazards

32. Adjustable transport tables

33. Guarding was invented

34. Education & Awareness • Soft tissue awareness training has been given to all employees • Understanding how soft tissue injuries occur and how to prevent them is the key • Earlier identification & employee awareness is important • With the right tools employees are able to identify there is a problem & look for solutions

35. This employee had wrist & elbow pain when she had to test this particular unit that required pinching, force & awkward posture

36. She informed the person who designed the testing process & changes where made. The employees satisfaction in solving this problem can’t be measured

37. 2010 H&S program highlights Continued Management commitment! Building on what we have. Regular audits (5*22) Improve RTW and Modified work programs Improve accident reporting Updated presentation given to all employees Safety incentive program started

38. Other aspects of our Wellness Program (H&S) Nutritional awareness Smoking cessation Canada Fitweek Special events First Aid Attendants appreciation Blood Pressure Monitoring Weight loss program (Weight Watchers at Work) Ergonomic training New emphasis on Exercises

39. RESULTS OVER THE PAST 8 YEARS • The number and Severity of accidents have decreased • Lost Time Days for 2002 = 1731 • Lost Time Days for 2003 = 752 • Lost Time Days for 2004 = 338 • Lost Time Days for 2005 = 113 • Lost Time Days for 2006 = 384 • Lost Time Days for 2007 = 86 • Lost Time Days for 2008 = 669 • Lost Time Days for 2009 = 329

40. Safety is never ending !IMG’s Goal is Zero accidents and that everyone can go home safely enjoying activities outside of workIMG has seen dips in our progress But our goal is continuous improvements

41. Remember whether at Work or at Home “Take Time for Safety”

42. Questions ?