#LeanAndSafety21 Member Campaign

Staying safe is a top priority for LCI corporate members. Respect for people is a cornerstone of the Lean culture and cannot be achieved unless the safety of all team members is put above all else. Check out each LCI corporate member’s #LeanAndSafety21 photos below to see their Lean safety innovations!


#LeanAndSafety21 Member Campaign Winner

Interstates won the member campaign with these three #LCISafety photos and will host a LCI Safety Webinar.

Interstates, Inc.

Our crews use thread in place methodology to thread conduit up in the lift, which allows for the safe threading of conduit while up in our JLGs or lifts. Our crews are able to continue working up in the air with the threader in the basket, eliminating the step of going back down to the ground station to thread the conduit. Some additional safety benefits include:

  1. Less up and down in the lift, which reduces the possibility of hitting items during motion.
  2. Less operator fatigue entering and exiting the lift.
  3. Less chance of incorrectly putting on the safety harness because of reduced cycles.
  4. Work holding vices to allow for safe one-person operation of cutting and threading conduit when in the lift.
  5. Storage bins are located in the lift to hold tools and materials, which reduces repetition injuries lifting tools and materials off the lift floor.
  6. Focused work task reduces distractions.

Cable tray cutting guides is another lean method we recently implemented. This tool improves safety and productivity for cutting cable tray and drilling splice plate holes. To aide in cutting, they provide a square edge to allow a circular saw with aluminum blade to ride along during the cutting of the tray. They also provide drill bushing holes for the proper location of the necessary splice plate holes. Cutting guides allow ladder tray to be cut with only two cuts versus four with previous methods. Additional benefits of the cable tray cutting guides include:

  1. Cut guide secures to tray piece being cut allowing operator to hold saw with two hands.
  2. Cut guide provides smooth surface for operator to operate the saw. Previous methods had the saw dipping down into the web of the cable tray.
  3. Cut guide allows cut to be performed in one operation. Previous methods required multiple cuts to sever one side of the tray.
  4. Drill guide allows accurate drilling of holes using secured drill guide. Previous methods used a splice plate that even when clamped was not as secure.

Another lean approach is switching from a ground strap drilling operation to a punch operation. When you have a thin metal ground strap that needs a ½” hole drilled through, our previous process was to clamp the ground strap and drill the hole through the strap. We learned that effectively clamping a thin metal strap is difficult especially on jobsite conditions. In addition, hand drills have their own inherent risks when drilling through metal. We discovered that a metal punch tool would be more effective and allow for safer work practices. The safety advantages of the punch tool include:

  1. A punch tool operation does not require material clamping. With ground strap drilling, effective clamping is difficult on thin grounding metal.
  2. A punch tool operation eliminates the twisting motion, which is normally transferred to the operator using a ground strap drill.
  3. A punch tool does not create metal debris that can get in the operator’s eyes or hands.
 

#LeanAndSafety21 campaign entries

Turner Construction

 

Picture 1: The approach of having a QR code with signage, that takes an individual to a site to upload all safety documentation for the jobsite, rather than hand carry it to the GC Safety Manager for processing, has dramatically improved the amount of time that the safety professionals get to spend in the field, assisting workers and ensuring everyone goes home safe each and everyday. This led to less injuries and incidents on site, more oversight from safety in the field, and an improved safety culture.

Picture 2: Rebar cages built at height, above ground, for the footings of the building. Typically in the past, the personnel would get into the excavation, into a very tight area, constantly bending over to tie rebar. With this method of building everything on stands, above ground, no personnel had to get into an excavation or bend over at all to tie rebar. This led to significantly less sprains/strains and other injuries on site.


Southland Industries

 

Picture 1: NextCode In-House EHS Software: We have been developing a web-based safety program specifically to cater to Southland’s needs and facilitate safety participation for all Southland employees. This program reduces the amount of time our safety professionals spend on documenting audits or inspections, organizing or preparing various training such as new hire orientations, weekly safety tailgates, and lessons learned while introducing and reinforcing Southland's Safety Culture, Core Values and safety training expectations to all employees at a touch of a finger. This method of conducting and capturing audits, reports, and training documents facilitates our managers and supervisors to do other important tasks and allows them to spend more time on the job-sites with our field employees where their time is more valuable.

Picture 2: Prevention Through Design: Southland has always been a leader in the industry when it comes to utilizing prevention through design to help us reach our goal of zero injuries. For many years, we have embraced lean concepts and continually improved upon maximizing the use of prefabrication. We utilize our shops to fabricate material in a controlled environment to reduce the amount of risk and exposure to the employees in the field while increasing overall production. Southland’s Mountain West Division is using Building Information Modeling to eliminate risks before it occurs on the construction site. We are taking Prevention Through Design to the next level. Prevention through design using modeling is the concept of mitigating occupational hazards by designing them out. We believe hazards and risks are more effectively and economically addressed by this process. Using BIM allows Safety Professionals to walk the job virtually and identify key risks and opportunities associated with a project before construction begins. Fall protection is a key opportunity when using modeling. We use the model to identify leading edges, access and egress points, openings and skylights, elevator and mechanical shafts, loading and landing zones, and other related hazards. After these fall hazards are identified, we design cast-in-place fall protection anchor points. Safety professionals are able to access the model and insert anchor points that will translate into Trimble GPS Points in the field. Trimble equipment uses GPS technology to map out installation points during the decking phase. The Cast-in-place anchor points are then installed before the concrete is poured. This eliminates the risk and exposure of the employee needing to drill in overhead safety anchor points after the concrete is poured. BIM can also be used to determine excavation protection systems. Safety professionals can access the model and take measurements of the excavation depth and dimensions. We also have the ability to identify confined spaces in the project and plan for accessing these areas early on. We firmly believe that being proactive by utilizing prevention through design to its full capabilities plays a large role in reducing our injury rate and ensuring our greatest resource returns home to their families each day.

Picture 3: Safety Box

The Safety Box is a lean improvement we have implemented in the Mountain West Division Highlights:

  • Proper storage of fall protection.
  • All PPE and safety equipment is accessible and organized in the field.
  • All safety signage and inspection forms in the field including inbox/outbox.
  • Eyewash, fire extinguisher, and first aid kit located on the front exterior of the box.
  • Whiteboard located on the back of the box. Whiteboard includes:
  • JHA.
  • Pre-task plan.
-Site Emergency contact information
-PPE requirements with SI employee picture.
-A reference guide to site-specific safety manual & foreman's manual.
-ANSI hierarchy of controls display.
-Assured Grounding Program.
-Site evacuation map and instructions.
-Accident reporting and control procedures.
-Safety paperwork requirement matrix.
-Stretch and flex program with pictures.
-Heat illness prevention program.
-Hazard communication program.
-OSHA 300A Log.

 


Dome Construction

 

Photo 1: DCC utilized 5S to identify waste in Safety Documentation, Orientation, Job Hazard Analysis (JHAs), and Pre task planning (PTP) with the old paper/binder method and through this analysis utilized a Kanban Board to help us map out creating an internal (now external) application for our safety needs called eMODwhich we also modified to help us deal with Contact tracing and pandemic check-lists.

 


CRB

 

Photo 1: Lean approach used is Prefabrication Preassembly Modularization Offsite Fabrication (PPMOF). Central utility plant modules are transported from a prefabrication warehouse. PPMOF saved 30,000 hours of site labor on this project, resulting in safer working conditions. In the second photo you will see preassembled central utility plant modules are brought onto the project site and installed. PPMOF saved 30,000 hours of site labor on this project, resulting in safer working conditions.

Photo 2: Lean approach: PPMOF. Preassembled central utility plant modules are brought onto the project site and installed. PPMOF saved 30,000 hours of site labor on this project, resulting in safer working conditions.

Photo 3: Lean approach: Prevention through design

Architects and laboratory planners studied the standard operating procedures and built subtle safety reminders into the design. Black countertops are for research activities and white countertops are for non-research activities. We also implemented wall and floor color at each safety stations to augment the required safety signage. By using glass, scientists can see each other from enclosed spaces, allowing for quicker response in an emergency. *photo credit Connie Zhou photography


Alberici Constructors

 

Photo 1: Continuous Improvement: In the spirit of continuous improvement, Alberici is making the change from traditional hardhats to construction safety helmets. Our classic orange hardhat represented the latest advancements in head protection for our workers when they were rolled out more than 20 years ago. As the construction industry has evolved, so too has safety technology. As one of America’s safest companies, we continuously advance workforce safety in our unyielding quest for zero injuries. After evaluating multiple hardhat/helmet styles and vendors, we found that safety helmets offer superior head protection, including greater defense against impacts to the front, back, and sides of the head. They also feature an integral chinstrap to keep head protection in place in the event of a fall, while leaning over, or looking up. Our new construction safety helmets will be rolled out to all Alberici project sites by the end of April 2021.

 


Gilbane Building Company

 

Photos 1 & 2: From previous fall protection lessons learned, we increased the parapet wall height to eliminate the fall protection issues challenges on the roof and life-long benefit for end-user. This improved safety planning helped us to keep the schedule moving forward without any safety issues – Safe production! During the renovation project's design process, we have worked with the end-user and provided the permanent solution for fall protection issues.

Photo 3: From previous lessons learned, we designed advanced lifting anchorage for 30-ton precast panels, which were installed during the manufacturing process. These improved Lean practices helped us to increase safe productivity, resulting in excellent efficiency and safety blend.


Southland

 

Photo 1: Our Daily Job board helps to instill Southland's core value of safety. The Hazards and Controls column is populated by the crew working on the task during our morning huddles. This allows them to think about what can go wrong, what they can do to mitigate the hazards, and what tools/PPE they might need to safely complete their tasks. There is also an afternoon meeting prior to quitting time to fill out a Plus/Delta sheet, so the team can continue to improve and eliminate inefficiencies.

Photo 2: Due to Covid-19, we've incorporated a daily safety routine of cleaning our work areas and tools to ensure everyone feels safe. Every morning and at the end of each day (at minimum) a crew member cleans and disinfects all shared tools and Gang Boxes with a named brand cleaning solution. This also ensures our teams are doing everything they can to prevent the spread of the virus. This simple action has had a positive impact on the moral and helps everyone know that we're doing our part to remain safe, while also staying in compliance with current safety protocols.


Dimeo Construction Co.

 

Photo 1: Reducing waste by closing the gap between work as done and work as planned through use of P.E.M.E. based worksheets to analyze and plan work.

Photo 2: The use of visual mockups using anthropometric data, equipment manufacturer BIM data and scaled model of building provides a reliable process to evaluate worker and equipment capability without mobilizing equipment. This reduces transportation waste and mitigates unnecessary work at elevation.

Photo 3: Making the case for 360 degree photographs and file sharing technology to improve work planning and reduce unnecessary entry into potentially hazardous spaces and reduce transportation waste


Skiles Group

 

Photos 1 & 2: Continuous Improvement As a Lean construction implementer, Skiles Group is constantly seeking better ways to operate and achieve more value,”. Skiles Group created Smart Safety Alert, a geolocation/geofencing technology to deliver custom emergency notifications and instant access to critical information to workers’ phones on the jobsite, enabling teams to save time, and potentially lives, in responding to emergency situation The inspiration for the technology was born from frustration with conventional alert methods, such as horns, flags or posters for emergency response. We developed Smart Safety to deliver real-time, jobsite-specific information and instruction to workers’ phones to improve communication and response times for emergency situations.”

Skiles Group initially created a value map for the current state of crisis management vs the future state with the Smart Safety App. Attached is a graphic showing the improvement.

 


Dome Construction

 

Photo 1: Everyday on the jobsite crews are required to complete pre-task plans, “PTP” prior to starting work. These daily safety plans include tasks, steps to complete tasks, hazards associated with task and mitigation plans. Prior to eMOD our field crews were given a blank PTP form to complete. The field crews completing these documents seemed to understand the task and steps but when it came to identifying hazards and safe plans they came up short, we would always see the same ideas including - None, Be safe, Don’t get hurt, 360 awareness, PPE. It was clear that we were requesting our field teams both internally and externally to complete this documentation without actually training them on what type of content we are looking for. eMOD provides suggestions for potential hazards and safety plans. It points people in the right direction and promotes critical thinking. Companies are able to customize their database for PTP and help promote and build a knowledge base for their crews. With eMOD's PTPs we are able to focus field crews attention on safety and not the administrative paperwork.

Photo 2: At Dome Construction we require our superintendents to complete daily safety inspections of the jobsite. In the past we had been using another software tool for these inspections but found that site safety inspections were not getting completed on a regular basis. As we did more investigation into why these were not being completed we found that the options of pass/fail on an observation was a hard answer. As a superintendent myself, the idea of saying I failed in a certain area was hard. Now that we have switched over to eMOD not only to we have compliant and non compliant observations we can also provide safety recognitions. Within a safety recognition we are able to tag specific people in the field and give them kudos for their actions in the field. Safety inspections tend to have a negative connotation that they are going to result in a list of all the things you need to fix. There are not enough “thank you” in the field. With eMOD we are able to give kudos where they are deserved.

 


CG Schmidt Inc.

 

Photo 1: The Somero Sky Screed 36 is a stationary laser screed machine. We are using it on a multi-story building to finish the concrete slab on metal deck. The machine is equipped with lasers to ensure proper concrete thickness and flatness. This was a substantial investment that is safer and provides the building owner with a better finished product than the traditional method. Benefits include significantly reduced exposure to carbon monoxide and gas engine fumes compared to a typical power screed. It eliminates the risk for a musculoskeletal disease relating to the vibration from power screeds and concrete vibrators. No more strains and sprains from lifting the equipment, the Sky Screed is moved with the tower crane on site. Noise exposure is also reduced compared to the typical methods by removing the multiple gas engine equipment that would be used to perform the same task. Our crews are pretty happy and more importantly healthier with the use of the Sky Screed.

 


Turner Construction

 

Photo 1: The 30 Otis project partnered with David Long and completed an A3 on the window wall installation. During the process of the A3 it was noted that the employees were handling each panel manually to set them into the track at the edge of the building. This presented multiple handling opportunities for something to go wrong. The team switched over to utilizing a manipulator to set the glass panels. This machine would grab the panel from the storage crate via four suction cups. The glass panel would stay on the manipulator until it was place in its final resting place and was secured.

 


See the 2020 Photo Campaign Winners


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