Manufacturing Sector Action Plan to 2013

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3. Planned and ongoing activity to 2013

The goals

Ultimately, we want to see:

Safe use (and design) of machinery

Safer use of vehicles

Reduced injury, fatality and disease for at-risk groups, and

Information gathered which can be used to identify future trends and emerging issues for the manufacturing sector.

The approach

In order to achieve these goals, we need to have a multi-faceted approach. This involves:

Building health and safety leadership

Making sure people have the right skills and the confidence to contribute to and apply improved health and safety practices in their workplace (capability)

Making sure people have the information they need - about the problems and the solutions (knowledge), and

Effective systems and processes that bring about behaviour change (infrastructure)^[9].

The actions

The following actions (current and planned) of industry stakeholders and government have been mapped against the goals and the approaches using the icons above, so you can see how they work together.

3.1 Establishing clear safety standards for machine guarding

Part of making information accessible and easy to use is to make sure it is relevant, clear and easy to understand.

Over the next two years, the Department of Labour will work with key sector stakeholders, (e.g., ITO’s, business organisations, users and engineers) to review and improve the content of health and safety standards and guidance relating to machine guarding. We want standards and guidance to be clear and accurate, with easily understandable obligations and consequences for all parties.

3.2 Delivering effective training to the manufacturing sector

3.2.1

NZMEA (New Zealand Manufacturers and Exporters Association) offers a range of health and safety training - from workshops on HSNO Approved Trainer Handling, to forums such as Occupational Hygiene and Minimising Workplace Exposure, Health and Safety in the Workplace, and Machine Guarding Safety. Workshops and forums are held throughout the year and will continue to 2013 and beyond.

3.2.2

FITEC (Forest Industries Training and Education Council) aims to improve health and safety practices, for example safe machine guarding and safe vehicle use. FITEC will work with key manufacturing sector stakeholders, including the New Zealand Qualification Agency (NZQA), to increase the availability and uptake of recognised training and education to everyone in the manufacturing sector. This initiative will run to 2013 and beyond.

3.2.3

ACC will continue, over the next two years and beyond, to focus on its Frontline Leadership programme. The programme aims to increase the number of people in the manufacturing sector doing workplace safety training. The emphasis is on practical training that helps build a positive workplace safety culture and leads to fewer on-site workplace injuries. The programme targets manufacturing employers, frontline supervisors, and health and safety representatives.

3.3 Developing guidelines for safe work in the metal industry

The Metal Manufacturing Safer Industry Group (MMSIG) has developed the Metal Industry Guidelines for Safe Work. These guidelines provide practical solutions for managing a range of typical hazards.

ACC will work with MMSIG to develop an online worker induction package, and health and safety resources for use in staff training. This will be completed by December 2013.

3.4 Collaborating internationally on the safe use of machinery

EMA Northern is working with the International Labour Organization (ILO) on a code of practice for the safe use of machinery. The code’s objective is to protect workers from the hazards of machinery and to prevent accidents and incidents resulting from using machinery at work. The development, approval, and review of this document will continue to 2013 and beyond.

3.5 Reducing injury and harm caused by poorly guarded machinery

Poorly guarded machinery and the lack of associated safety procedures remains a significant cause of death and injury in New Zealand’s manufacturing sector. All machinery must be adequately guarded or made safe by being positioned out of reach of employees. Documented procedures are also required to show employees how to safely work with machinery.

In July 2010 the Department of Labour began a three-year nationwide compliance project designed to reduce the unacceptably high level of fatal and serious harm injuries associated with the unsafe use of machinery. The project focuses on types of machinery that are commonly involved in accidents and incidents (and for which there are clear safety standards). The project aims to:

raise awareness across the manufacturing sector of the real and preventable risk resulting from poorly guarded machinery and/or the lack of associated safety procedures
address the failure to put into place basic machine guarding practices, many of which are well known and have been understood for many years
address the failure of employers to undertake effective hazard identification and control
address a decrease in the knowledge of machine guarding standards by duty-holders by producing revised guidance material to provide practical information on how to safely use machinery in the workplace, and
sharpen our data collection and dissemination - by working with the sector to gather and share knowledge about the sector, particularly information that enables current and future trends and issues to be identified, and that assists us with the design of future projects.

During this project the Department will explicitly and publicly target non-compliant workplaces. Actions taken by inspectors will be a tailored combination of the primary interventions – engagement, education and enforcement.

The project will continue until at least 2013.

3.6 Promoting the safe use of forklifts

Contract Logistics holds an annual forklift competition to test the forklift skills and work practices of their workers (as well as a way of encouraging their forklift drivers to up-skill themselves). Originally an internal competition, in 2011 the competition was opened up to other businesses. The competition became a team event, focusing on practical activities that forklift operators regularly undertake - such as safe and correct palletising of goods, loading MAXI/ULD cages and sorting of dangerous goods. This competition is expected to run to 2013 and beyond.

3.7 Reviewing, improving and setting company safety standards

Over the next two years and beyond, Fonterra’s health and safety management team will work with managers, health and safety representatives and front line staff at all of their sites (national and international) to review, improve, and set company standards for:

the use of forklifts
warehouse traffic management systems
racking design, maintenance and operation
machine guarding, and
driver safety.

3.8 Working in partnership

Workplace health and safety is everyone’s business. We all have a part to play. Relationships, networks, and collaborations at all levels (government, sector, and within each workplace) will be an important part of reducing the manufacturing work toll.

3.8.1

Over the next two years, the Department of Labour will build a range of relationships with stakeholders in the manufacturing and other high risk sectors to find ways of working together to reduce the work toll.

3.8.2

The Partners in Action Pledge is a symbolic acknowledgement of the collaborative approach required between government and other sector stakeholders to reduce the work toll. The Department of Labour will promote the Pledge in the manufacturing sector over the next two years (via a variety of networks and events) to encourage stakeholders to sign up. By signing the Pledge, businesses, organisations and individuals are agreeing to do their bit to reduce the work toll.

3.9 Supporting improved literacy and numeracy

Research shows that about four in every 10 New Zealand employees have difficulties with reading, maths, and communication. The country’s poor adult literacy rates have long been considered a serious issue that costs businesses - through accidents and injuries, high wastage, mistakes, missed deadlines and low productivity.

3.9.1

The Joinery ITO works to improve the literacy and numeracy skills of people in the joinery and glass industries who are undertaking formal training.

Over the next two years and beyond, the Joinery ITO will continue to develop their resources and strategies for both employers and trainees in these industries.

3.9.2

Competenz is taking the initiative to increase the literacy and numeracy skills of New Zealand’s workforce by embedding appropriate material into all Competenz-produced qualifications. This material aims to raise trainees’ literacy and numeracy skills while they learn and progress in their trade. Exercises and examples are provided to make sure learners understand what they’re learning and can apply it in their everyday work.

Competenz assesses trainees before and after training, to make sure the embedded material does lead to an improvement in literacy and numeracy skills. Client companies are informed of their trainees’ progress, and Competenz endeavours to provide continuing support for a trainee if they need it, once they finish formal training. The project will continue to 2013 and beyond.

3.9.3

The Department of Labour has developed a website for employers to access information and tools that will help them assess their workplace and to address this issue. Improved foundations skills help make for safer workplaces. www.skillshighway.govt.nz has several high level assessment tools employers can use to find out how their workforce is affected and where they can go for help. The Department will continue building on this work.

3.10 Making safety information more accessible to workers with literacy and numeracy issues

3.10.1

The Apparel and Textile Industry Training Organisation (ATITO) has implemented an embedded literacy and numeracy programme across all its manufacturing sectors. This includes the use of laminated sheets that are displayed on machines and equipment. The language is clear and unambiguous and uses pictorial images strategically to replace words. Resources are freely available to all workplaces where there are trainees working towards national qualifications. This will be available to 2013 and beyond.

3.10.2

Competenz is shifting from bookwork to e-Learning as a way of embedding literacy and numeracy, and health and safety concepts. E-Learning is used by many leading manufacturers worldwide, and is a proven method of delivering effective 24/7 training. The project will roll out in 2012 and continue to 2013 and beyond.

3.10.3

A health and safety induction DVD is being developed in a collaborative effort between the NZ Marine ITO Health and Safety Committee, the Department of Labour, and others. The DVD supports the health and safety study note unit standard already developed for new apprentices by the committee. Work on this and other resources will continue to 2013 and beyond.

3.11 Promoting safe work practices to youth

3.11.1

Competenz is using a welding simulation game to promote the manufacturing sector to New Zealand’s youth. The game will be used in secondary schools as part of the Technology and Manufacturing Pathway programme. The simulation contains videos, quizzes, and messages that reinforce health and safety. This preventative approach aims to equip learners with key knowledge of health and safety concepts before they enter the workforce. This promotion will continue to 2013 and beyond.

3.11.2

Competenz also supports the safe operation of machinery and vehicles by working with youth trainees for several months after they complete training to ensure they continue to use them safely. Continued safe work practices are rewarded with a Competenz Competency Certificate – encouraging youth workers to work safely. This initiative will run to 2013 and beyond.

3.12 Accessible online training for discomfort, pain and injury (DPI)

ACC will make their Disability, Pain and Injury (DPI) training programme more accessible by making it available online. The aim is to increase the number of employers in the manufacturing industry complete DPI training, and join the programme. This will be completed by 2013.

3.13 Supporting best practice in the workplace

NZ Manufacturers and Exporters Association (NZMEA) support best practice in the workplace by providing a variety of forums, workshops and longer programmes to keep employers updated on their workplace obligations. These cover different subject areas important to manufacturers such as lean manufacturing, human resource practice, and health and safety. This will continue to 2013 and beyond.

3.14 Providing health and safety representative training

From April 2012 NZCTU Te Kauae Kaimahi will be running their new health and safety 20198 unit standard course. This is a Level 4 course that is recognised by NZQA with 8 credits. People credited with this unit standard are able to:

define the role of the health and safety representative in the workplace
identify the requirements of the Health and Safety in Employment (HSE) Act 1992
outline the functions of hazard management under the HSE Act
identify the training requirements for hazard management under the HSE Act
identify the requirements for dealing with emergencies
identify the requirements for reporting, recording and investigating injury and incidents, and
identify the requirements for rehabilitation under the Accident Compensation Act 2001.

This course is expected to run to 2013 and beyond.

3.15 Supporting improved safety through lean manufacturing

Lean manufacturing offers companies the ability to improve workflow, increase productivity, lower costs (including those associated with lost time due to injury), and increase staff morale. This includes improving work systems to support good health and safety practice, e.g., work stations laid out to improve flow and to reduce the need for manual handling of materials. The lean culture creates an engaged workforce, and engagement fosters an increased awareness of health and safety requirements in the workplace.

3.15.1

The Joinery ITO will continue to work with providers over the next two years and beyond to offer lean or competitive manufacturing training to the joinery and glass industries.

3.15.2

NZMEA and NZPICS offer people in the manufacturing sector the opportunity to gain an internationally recognised qualification, via the Certified in Production and Inventory Management (CPIM) programme. The programme is made up of five modules. Included as part of this training are regular forums on all aspects of lean manufacturing. This training will continue for the next two years and beyond.

3.15.3

Competenz contributes to increasing company capability through lean/competitive manufacturing by working with manufacturing companies to undertake thorough needs assessments that recognise current competencies and establishes areas of weakness. Competenz develops training plans to implement lean practices and processes into the companies – ensuring that lean becomes part of the company culture. This training will continue for the next two years and beyond.

3.15.4

EMA Northern holds awareness seminars on developing high performance organisations through lean thinking.

Lean thinking improves productivity through the identification and elimination of non-value adding activities (waste) and provides the tools and processes to enable its elimination. It engages, involves, and empowers staff and builds positive workplace culture and relationships, which can lead to a safer working environment.

The most effective tool for business process improvement is value stream mapping (a technique used to analyse and design the flow of materials and information required to bring a product or service to a consumer).

The EMA provide 1 day and 3 day courses on Business Process Improvement for organisations to become faster, leaner, and smarter. These courses will run to 2013 and beyond.

3.15.5

Training employees in the principles of competitive manufacturing (lean) is regarded as the most important training employees can receive after induction and safety training. The Apparel and Textiles Industry Training Organisation (ATITO) takes a whole-of-company approach to competitive manufacturing, by working with business owners and plant managers to first evaluate the workplace and operations. Businesses are also encouraged to train all staff, including managers, in the National Certificate in Competitive Manufacturing. The main advantage of this programme is that it increases productivity and profitability by supporting full employee participation in decision making for their work areas and requires them to measure their daily performance and thereby encouraging a workplace of continuous improvement. This work will continue to 2013 and beyond.

3.16 Raising awareness for Pacific workers – ‘Come Home Safely’

Pacific workers have disproportionately high levels of fatality, injury and disease. The Puataunofo Group is a collaborative initiative involving a broad range of agencies and partners that developed the ‘Come Home Safely’ programme, which aims to improve health and safety outcomes. Primarily, the manufacturing sector is targeted and the message is tailored to Pacific people. The Puataunofo Group will work with other sector stakeholders in the Auckland region over the next two years to raise awareness of health and safety rights, responsibilities and obligations, and improve workplace safety practices for Pacific workers.

3.17 Defining best practice in Māori workplaces

The Department of Labour will identify those Māori workplaces that exemplify good health and safety practice, with a view to defining the common characteristics. This information will be used to develop a resource to help improve health and safety in workplaces across the manufacturing sector and other industries. This work will take place over the next two years and beyond.

3.18 Promoting WorkSmart tips tools for manufacturing

WorkSmart Tips is an online tool that allows employers to create tailored health and safety information for their workers. ACC will continue to develop and promote relevant injury prevention information for the sector (focusing on priority areas) in conjunction with targeted high-risk industries.

3.19 Engaging employees in health and safety

Contract Logistics has adopted several health and safety initiatives at their Highbrook site (Auckland) to ensure all employees and contractors know what is expected of them. This includes pre-employment literacy and numeracy testing to identify employee needs, updating the health and safety notice board with clear and concise information, and the development of kits for health and safety forms and documents.

Over the next two years and beyond, Contract Logistics will continue to look for ways to increase employee participation regarding health and safety, and make health and safety easy.

3.20 Introducing the ‘How safe are we?’ programme

The Plastics and Materials Processing Industry Training Organisation (PaMPITO), has developed a safety programme using nationally recognised qualifications (National Certificate in Occupational Health and Safety levels 1, 3, and 4) as benchmarks for assessing employees’ skills and competencies in health and safety. The programme identifies what employees already know and do in relation to these benchmarks, and where they might need more training. The programme provides structure to a company’s health and safety practices and a strong framework upon which to build the health and safety system. This programme will continue to 2013 and beyond.

3.21 Providing health and safety systems to help prevent harm

Activ-8 Health and Safety Systems will work with their client group to provide them with resources to effectively train workers in the manufacturing sector. This will be done by providing:

an on-line reporting system
competency testing and training needs assessment
e-training, and
promotion of prevention through design (PtD).

This work will continue to 2013 and beyond.

3.22 Building health and safety capability

Impac Services focus on building skills and capability amongst front line workers, supervisors, mangers, safety practitioners and directors to create a robust health and safety culture. They provide health and safety systems, processes and insights to keep clients up to date with health and safety requirements, and will continue to provide services to the manufacturing sector to 2013 and beyond.

3.23 Ensuring people manufacturing joinery products have the required knowledge and skills

Safely operating and maintaining fixed machinery is a key requirement for manufacturing joinery products. The Joinery ITO will continue to work with stakeholders over the next two years and beyond to set skill standards, advocate, and organise training to meet job requirements.

3.24 Supporting noise-induced hearing loss ‘noise at source’ initiatives

ACC will continue, over the next two years and beyond, to support research and develop programmes that promote solutions for ‘noise at source’ problems. The ‘SoundSafe manufacturing’ intervention will focus on three components: work environment, the organisation, and people. Further information and publications will be promoted on the ACC website and be distributed using the industry partners and channels.

3.25 Sharpening our data collection and dissemination

Reducing the manufacturing work toll requires a good understanding of the sector. Using and sharing a wide range of data will allow us to identify current and future issues and assist with the design of effective initiatives.

Over the next two years using relationships with other sector stakeholders, the Department of Labour will improve its collection and sharing of sector information on the number and causes of fatalities and serious injuries.

^[9] Further explanatory information about these general action areas and their contribution to improving health and safety performance can be found in the National Action Agenda 2010-2013