SAFESTART Success Stories

A Leading Aerospace Company
Renewing a Focus on Safety

Industry
Aerospace

Facility Location
United States

Background
A leading worldwide supplier of aerospace components, systems and services, with a plant site of several hundred employees, enjoys below average accident rates for its industry. Through a structured, plant-wide OSHA compliance training program, this American-based plant reduced accident rates by 54% from 2001 to December of 2002 (84% reduction in lost workday case rate during same period). However the Safety Project Leader for the main plant knew more could be done to achieve greater reductions in accidents.

Training Need
At the end of June 2002, the plant had already experienced ten OSHA recordables. The management team recognized that without a revitalized emphasis on safety, the plant was in danger of missing its year-end goals for accident reduction. To renew enthusiasm for safety and prevent the program from regressing, they felt they needed a behavior-based approach to safety training, but one that would complement their current OSHA training, not replace it. Management was looking to do the following:

Of the many behavior-based training programs available, they believed that only TWL Knowledge Group’s SAFESTART fit these criteria.

The safety project leader already experienced success implementing SAFESTART to 250 employees in his previous job. He understood the importance of building a diversified team of trainers who represent a variety of backgrounds (Human Resources, Environmental Health & Safety, etc.) and who are creative and can relate their personal experiences to employees. In his experience, this team-oriented method of training would ensure SAFESTART’s success.

Implementation
A training team was assembled in June of 2002 at the main plant in preparation for a SAFESTART training launch to employees in July of 2002. After conducting “train-the-trainer” sessions, the plant rolled out SAFESTART to its employees – holding classes every three weeks. Each 11/2 hour session included a variety of company representatives, from maintenance technicians to aerospace contractors.

Management chose the pilot program method (phased rollout) versus rolling out SAFESTART to all ten company sites because it wanted to prove the training worked before investing significant time and money. The pilot program targeted employees working in maintenance, repair and operations.

Results
Since implementing SAFESTART at the main plant (95% completion), the company has experienced only three OSHA recordables through December of 2002, a 70% reduction from January-June’s pace. This dramatic turnaround enabled the plant to exceed its goal for reducing OSHA recordables in 2002. In the safety project leader’s eyes, this is “icing on the cake. SAFESTART injected energy into our safety program and helped us avoid a culture of complacency.” He will be the first to say that SAFESTART is not the total safety training solution, but an integral part. “A company needs to have a strong OSHA compliance program to provide the building blocks for safety awareness training like SAFESTART,” he said. “The end of the program is merely the beginning of the process.”

To keep the SAFESTART program alive, the management team has held numerous safety parties including a SAFESTART cake party where employees received recognition for their commitment to the training program. In addition, signs were erected at all entry points to the plant reminding employees of the SAFESTART concepts.

With the success of the initial rollout of SAFESTART, implementations at additional company facilities are now underway.