- We launched our new HSE Strategy that ensures a proactive approach to changing behaviour by anticipating accidents before they happen
- Communication on Health and Safety has become a focus, with online ‘HSE Alerts’ being launched, as well as ‘Hi-Plus Announcements’ that share success stories throughout Knauf Insulation
- We are making leadership more accountable and our employees more responsible. For example, a set of Life Saving Rules has been put in place, including full compliance with the Lock Out Tag Out (LOTO) requirement when working on powered / energised systems.
- By the end of 2015, a total of 17 out of 30 plants had completed the ‘HSE Expectations Gap Analysis Workshops’ with all plants on track to complete the workshops by 2016. We aim to roll out refresher workshops every two years.
QHSE MANAGEMENT SYSTEM
Knauf Insulation follows the important International Management Standards. We are certified by one of the leading conformity assessment organisations, Bureau Veritas.
Knauf Insulation’s management system is based on the continual improvement framework outlined in:
- OHSAS18001 (Health and Safety Management) for all our Europe, US, Russia and CIS Plants.
- ISO 14001 (Environmental Management) for all our Europe, US, Russia and CIS Plants.
- ISO 50001 (Energy Management) for all our Europe, US, Russia and CIS Plants.
- ISO 9001 (Quality Management) for all our Europe, US, Russia and CIS Plants.
Spotlight on St Helens
This journey of Continuous Improvement (CI) began four years ago. Traditionally in manufacturing, health and safety was just another task on top of an already intense schedule. At St Helens, health and safety has become ingrained in day-to-day life. Today there are no health and safety inspections – only manufacturing audits that have integrated safety at every level.
All resources focused on achieving a vision to achieve targets for Overall Equipment Effectiveness (OEE) for production equipment. OEE means ‘on-time in full’ delivery performance with monthly targets for manufacturing costs, as well as for health, safety and environment.
Driving this vision are the Knauf Family Values of Menschlichkeit, Partnership, Entrepreneurship and Commitment. St Helens is ‘de-siloing’ functions, to encourage partnership, utilise employee ideas, encourage entrepreneurship and ensure continued engagement and empowerment. There are eight Knauf Family Values Ambassadors at St Helens who work on projects set by employees covering aspects such as new employee inductions, hazard spotting, training and social activities.
What does CI mean in practice?
Continuous Improvement workshops were introduced lasting up to 10 days to cover critical aspects such as organising a productive workspace (a productive workspace is safer); reviewing the state of equipment, ensuring everyone understands how it functions (with straightforward one page explanations); problem solving exercises and management presentation training to help operators achieve their plans.
How are new ideas introduced?
Anyone can submit an idea for improvement – including safety – to a scheme run by the Engineering Project Manager and Area Process Leaders. An idea is reviewed by the team and a decision made on whether to progress or not. Ideas are physically placed on notice boards that also communicate updates on Continuous Improvement projects, safety and general information.
And how is momentum maintained?
There are daily meetings that focus on the plant’s vision where all aspects of performance are reviewed and any violations – such as safety for example – are considered and countermeasures put in place to ensure improvement. Plant performance for the previous 24 hours is also reviewed together with a plan for the next 24 hours. Every week Process Leaders complete a Process Audit to ensure systems are maintained and every month another Audit is carried out by members of the Management Team to allow one-to-one discussion with process operators about concerns.
What do people think about Continuous Improvement?
“People in the plants are full of ideas. Continuous Improvement is an opportunity to get new ideas heard, to beat routine, to progress quicker and get up to speed. Previously we just copied what other people did. But through integrated safety there is more understanding. It’s a safe place here.” Mark Daly, Senior Process Operator in the Multi Pack System Area, St Helens.