Under the “Qualification Level” of
the FEM Program, Victaulic activities are now equipped with various lean tools to begin improvements in the areas of: Teamwork (Safety), Standard Work Flow, Kanban, Equipment, Quality and Supply Chain. Te annual safety audit performed by the corporate safety manager also was incorporated into the Teamwork element of the program. “Te minimum passing scores for the annual audit are progressively elevated to achieve the next level of FEM progress,” Says D’Amico. Once the effectiveness of the joint Safety/FEM initiative was apparent, Victaulic’s leadership team began its VPP journey by benchmark- ing against other metalcasters that had achieved VPP status, performing a
gap analysis of their safety and health management system against the VPP standards and putting the company on an action plan to Star Certification.
The Voluntary Protection Program
In the program, management, labor and OSHA work cooperatively to prevent fatalities, injuries and illnesses through a system focused on: • Hazard prevention and control. • Worksite analysis. • Training. • Management commitment and worker involvement. VPP recognizes the implementation
of effective safety and health manage- ment systems that maintain injury and illness rates below national Bureau of
Labor Statistics averages. “For the primary metals industry, you
have to have a three-year track record of recordable injuries below the indus- try average,” D’Amico said. (See also Table 1.) “From there, the rest of the requirements are standard.” Participants submit an application to their OSHA regional VPP coordinator, then undergo an evaluation. For Victaulic, the OSHA evaluation team plans to verify the effectiveness of the company safety and health management systems through: • Formal and informal employee inter- views—up to 50% of the workforce— to determine their working knowl- edge of safety and health programs and the VPP Program.
• Walking the production floor to verify
Table 1. Incidence Rates of Nonfatal Occupational Injuries & Illnesses per 100 Full Time Workers (2) OSHA Recordable Injury & Illness Cases
NAICS Code(1)
All Manufacturing
Primary Metal Manufacturing Foundries (All)
Ferrous Metal Foundries (Iron & Steel Foundries)
Iron Foundries (Ductile, Gray, Malleable)
Steel Investment Foundries
Steel Foundries (Except Investment)
Nonferrous Metal Foundries Aluminum Diecasting Foundries Nonferrous (Except Aluminum) Diecasting Foundries
Aluminum Foundries (Except Diecasting)
Copper Foundries (Except Diecasting)
Other Nonferrous Foundries (Except Diecasting)
Switchgear and Switchboard Apparatus Manufacturing
331524 10.2 331525 331528 335313 9.3 9.0 5.3
5.9 Not Listed
3.2 — 331 3315 33151 2008 2009 2010(3) 5.0 7.2
10.6 11.9
4.3
6.2 8.7 9.9
331511 12.0 11.3 331512 8.9 331513 13.7 33152 331521 331522 8.7 8.5 7.1 8.2 7.7 7.1 7.2 3.8 4.4
(+2.3%) 6.3
(+1.6%) 9.7
(+11.5%) 10.6
(+7.1%) 12.0
(+6.2%) 6.1
(-25.0%) 10.4
(+18.3%) 10.9
(+51.4%) 5.2
(+36.8%) 8.9
(-1.1%) Not
Listed 4.9 2.8
(-12.5%) 2011(4) 4.4
(NC) 6.1
(-3.2%) 9.6
(-1.0%) 10.7
(+0.9%) 10.9
(-9.2%) 7.3
(+19.7%) 12.7
(+35.1%) (+22.1%) 8.4
8.1
(-3.6%) 7.8
(-28.4%) Not
Listed 9.5
(+6.7%)
10.3 ----
4.2
(-14.3%) 2.6
(-7.1%) 2012(5) 4.3
(-2.3%) 6.2
(+1.6%) 9.5
(-1.0%)
10.7 (NC)
11.5
(+5.5%) 6.3
(-13.7%) Not
Listed 7.8
(-3.7%) 8.6
(+10.3%)
5.1 ----
8.7
(-8.4%) Not
Listed 4.4
(+4.8%) 2.7
(+3.8%) 3.3 6.5 5.5
3.2 ----
2.2 5.9 3.1 Not
Listed 1.6
2.7
4.1 5.8 6.3
5.9 4.9 8.3 5.0 4.4 Cases with Days Away, 2008 2009 2010(3) 2.3
3.2 4.6 5.0
5.4 4.9 4.1 4.1 3.4 2.4
(+4.2%) 3.4
(+6.3%) 5.1
(+10.9%) 5.6
(+3.7%) 4.1
Restricted or Transferred (DART) 2011(4)
2.4
(NC) 3.5
(+2.9%) 5.4
(+5.9%) 6.2
(+12.0%) (+10.7%) 5.6
6.0
(+7.1%) 4.7
(-16.3%) (+14.6%) 6.7
7.8
(+63.4%) (+16.4%) 4.5
4.3
(+9.8%) 5.7
(+50.0%) 4.7
Listed
2.7 ----
1.5 (-6.3%)
(-4.4%) 4.2
(+67.6%) (-26.3%) 3.3
Not
Listed 6.0
(-20.3%) (+27.7%) Not
4.8 ----
1.8
(-33.3%) 1.3
(-13.3%)
(1) North American Industry Classification System (NAICS) - United States 2002 (2) The incidence rates represent the number of injuries and illnesses per 100 full-time workers and were calculated as: (N/EH) x 200,000, where N = Number of Injuries and Illnesses
EH = Total Hours Worked by All Employees during the Calendar Year
200,000 = Base for 100 Equivalent Full-time Workers (working 40 hours per week, 50 weeks per year.) NC = No Change
(3) Includes % Increase (+) / Decrease (-) From 2009 (4) Includes % Increase (+) / Decrease (-) From 2010 (5) Includes % Increase (+) / Decrease (-) From 2011
Source: Fred Kohloff, Director of EHS, American Foundry Society December 2013 MODERN CASTING | 37 2012(5) 2.4
(NC) 3.5
(NC) 5.1
(-5.6%) 5.7
(-8.1%) 5.9
(-1.7%) 3.7
(-21.3%) Not
Listed
4.3 NC
4.9
(+16.7%) 2.1
----- 5.2
(-13.3%) Not
Listed 2.1
(+16.7%) 1.6
(+23.1%)
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