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There are many different types of safety concerns in any given workplace. Some of them are quite obvious and can be addressed without too much effort. Others, however, are more hidden and will require some very specific steps in order to identify them and reduce or eliminate the issue completely.

Catchball may sound like a game of throwing and catching a ball, and in Japan it is a game just as that. However, catchball is also a common business practice used in lean businesses during the strategy deployment phase of Hoshin Kanri or simply Hoshin Planning. Needless to say, it does not include the use of an actual ball. Instead, it is more of a figurative term used to describe the process of sharing thoughts, ideas, and comments regarding proposed business or process changes and improvements. Instead of tossing a ball from person to person, think of it more as tossing thoughts or ideas from person to person. Catchball is an active communication session where participates are urged to contribute in order to explore all possibilities and come up with diverse working solutions and ideas. During catchball questions are answered, strategies are explored, priorities are defined, and shared understandings are built. Just as meetings can be formal or informal the same goes for catchball sessions. However, one difference between a meeting and a catchball session is that in catchball everyone should be contributing, while meetings are often led by a manager or similar ranked personnel while everyone else basically listens and takes notes.

Workplace practices for keeping employees safe and improving the safety of their environments has improved vastly over the past century. While part of this improvement comes, without a doubt, from the vast leaps in technology. An equally important piece of the puzzle comes from what we've learned from experience. For the most part, processes that don't work get phased out while those that do get brought conveniently to the forefront of publications and articles to help industries constantly re-invent and improve their "best practices" for safety. One system we're glad to see making its exit in recent years, is the "simple" safety system, in which safety statistics and decisions are based almost exclusively on the opinions of management and the actual reported accidents and injuries that occur on the job. While the latter part of that system can provide useful data, it is reactionary rather than preventative, and requires someone to get injured or property to get damaged before corrective measures are taken.

The term HAZWOPER stands for Hazardous Waste Operations and Emergency Response Standard, and is a set of standards created by OSHA. These standards are specifically applicable to five groups of employers/employees according to OSHA, but they can also be used by many other facilities looking to improve their hazardous waste safety.

A3 image via Reliableplant.com Today, I was looking for a decent A3 problem-solving template for an engineering friend who was planning on implementing a lean program for his company, and I came across a helpful article on ReliablePlant.com by Larry Rubrick and a cool A3 powerpoint presentation at PowerShow.com (don't hit download, just hit play). As many people may know, the A3 format originated around the type of paper (A3, 11″x17″ sheet) that the Toyota Production System engineers used to base their problem-solving templates - with the mindset that using only one piece of paper kept the thinking process focused and simple. The A3 is said to be one of the main building blocks of Lean thinking. On the report, a problem is identified and then it follows a process of successive stages (including objectives or goals) by which it may be solved, or at least lessened. I liked the examples Rubrick offers in his post, starting with the requisite Toyota A3, and moving on to others, including an A3 at Ford in the United States (which is meant for a typical copy paper size, 8.5 X11). Other A3s can end up getting more illustrative, but the gist of it is best represented in the simplicity of the TPS template, I think.

Jeff Moad's article "Manufacturing's Profile Rises, But Not Among the Young" on the Manufacturing Executive website ponders a recent survey by Deloitte, LLP and the Manufacturing Institute between "old school" views of manufacturing in America versus the younger generation's apparent lack of faith in manufacturing as a base for our country's economic stability.

To those who are used to a warehouse environment, walking through the maze and sorting out the various items safely might sound like a walk in the pack. To the visitors or new employees it is a different story altogether. Huge warehouses can be quite complicated especially with the various equipment's and different chemicals everywhere. There is hence a need for vigilance to ensure all the relevant people are informed on how the operations within the premises are run. Safety Safety within the warehouse is vital if the basic objective of an organization is to be achieved. It is imperative that the employees and any visitors feel safe within the workplace precincts. Warehouse signs can play an important role in this. Warehouses can be dens of danger if there are no adequate safety measures in place. Studies have shown that hundreds of workers die every year from work related injuries. These can result from; electrical faults, contact with hazardous chemicals, tripping from a slippery floor, a blast from explosives or from a forklift gone wrong. The hazards are many and so are the solutions. There are tens of stipulations on how employees' safety can be safeguarded but the most important of them is through the use of signs. Labeling of the various hazard areas can go a long way in ensuring that employees and visitors are adequately informed of the lurking dangers and appropriately informed on the precautionary measures to take. Effective signs The key purpose of signs is to inform or convey a specific message to another individual or individuals. Warehouse signs serve the same purpose and ensure that employees are well informed of what they are expected to do. To achieve this hence these signs should be well designed and written. The message to be conveyed should be clear with no room for ambiguity. The signs should be written in a language that is easily understandable to all without discrimination. If English is used, it is important to use another common lan

The piping in many facilities can get quite elaborate, with different pipes going in virtually every direction. The fact that each pipe is used to transport different solutions, makes it is absolutely essential that you follow pipe marking best practices in order to keep everyone safe. It is not enough to simply have the pipe labeled right at the spout or faucet, though that is certainly a good start. You also need to make sure the rest of the pipe is clearly labeled so that people who are performing maintenance or other work on them will not have any issues knowing exactly what is contained within the pipes. With that in mind, take some time to review the following 10 best practices for pipe marking, and double check to make sure your facility is up to speed. 10 Best Practices for Pipe Marking Best Practice #1 - High Quality Labels Labeling pipes is not an easy task. In most cases, these pipes are located quite high in the facility, so working on them comes with its own set of hazards. In addition, it can be time consuming and disruptive since you will need to use a ladder or lift to gain access to all the pipes. With this in mind, you always need to make sure you are labeling your pipes with the highest quality label stock possible. Vinyl labels, for example, will stick well to the pipes and can last for years. If you are labeling a pipe that carries steam or hot liquids, you will want to make sure to choose pipe marking labels that are specifically designed for high temperature. When you use the highest quality labels, you won't have to replace them again for many years, which can help keep your facility safe and running smoothly. Best Practice #2 - Standard Color Labels It is always a good idea to follow the industry established guidelines for the color of the labels you use. ANSI has a color scheme that is largely used across all industries, which effectively makes it a best practice. Even if you are not legally required to follow this set of standa

Arc flash is a problem that can cause enormous property damage and even loss of life. It is when an electric current jumps a gap between phases or a fault in the terminals. This electrical arc contains enough juice and heat to turn everything in the vicinity to a plasma projectile, and creates a pressure wave capable of blasting a person across a room! Knowing the potential threat arc flash poses, it is important to know arc flash protection guidelines as dictated by OSHA , NFPA 70e, and IEEE 1584. This includes tooling, PPE, and all standards for proper arc flash labels for proper category rating. Arc flash injuries and property damage can be prevented. You need to properly equip your workers with the correct personal protective equipment (PPE) and training information. The other day, I was looking online for examples of arc flash accident videos, and I came across this one (WARNING: This video is pretty graphic - it's not fully known whether the guy in this video was okay or killed, which perfectly displays how dangerous arc flash really is):

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