vii
Contents
Preface .............................................................................................. xi
Acknowledgments .......................................................................... xiii
About the Author ..............................................................................xv
1  Safety, Health, and Environmental (SHE) Pillar: Foundation
of Lean Continuous Improvement ...............................................1
1.1 Beginnings of Lean and TPM ............................................................1
1.2 James Womack and Lean ...................................................................3
1.3 TPM .....................................................................................................4
1.4 The Safety, Health, and Environmental (SHE) Pillar .........................6
1.5 The Value of Safety, Health, and Environment ...............................10
1.6 Zero Accident and Incident Vision ..................................................14
1.7 Strategy for Eliminating Accidents and
EnvironmentalIncidents ............................................................16
Endnotes ....................................................................................................20
2  Autonomous SHE .......................................................................23
2.1 The Path toward Autonomous Safety/Autonomous SHE ................23
2.2 Proactively Removing SHE Risk .......................................................31
2.3 Integrating the SHE Pillar with the Other Pillars ............................33
Endnotes ....................................................................................................34
3  Preparation Phase: Layingthe Foundation
forSHEExcellence .....................................................................35
3.1 Management Commitment and Living Leadership..........................35
3.2 Assessing Organizational Readiness ................................................39
3.3 SHE Vision and Values .....................................................................41
3.4 Zero Accident and Incident Education ............................................43
3.5 SHE Loss Tree ...................................................................................46
3.6 SHE Governance: Form Follows Function ......................................49
viii ◾  Contents
3.7 SHE Targets and the Balanced Scorecard .......................................51
3.8 6S (5S for SHE) .................................................................................54
3.9 Lockout/Tagout and Zero Energy State (LOTO and ZES) ..............62
Endnotes ....................................................................................................64
4  Integrating SHE into the Autonomous Maintenance Pillar .......67
4.1 Overview of the Integration of
AutonomousMaintenanceandSHE ................................................67
4.2 AM Step 1: Initial Cleaning and SHE ...............................................68
4.2.1 Danger Anticipation and Experiential Training ....................70
4.2.2 SHE F-Tags .............................................................................72
4.2.2.1 One-Point Lessons (OPLs)........................................73
4.2.3 Incorporating Safety into Cleaning and Inspection Plans ....73
4.3 AM Step 2: Countermeasures to Sources of
ContaminationandSHE ...................................................................76
4.3.1 Elimination of Sources of Leaks, Spills, and Dust ...............76
4.3.2 Elimination of Hard-to-Access Areas ....................................76
4.3.3 Zero Leak and Spill Campaign .............................................77
4.4 AM Step 3: Tentative AM and SHE ..................................................78
4.4.1 Including SHE in Provisional Standards ...............................78
4.4.2 Use of SHE Visual Indicators and Controls ..........................78
4.4.3 Pointing and Naming Drills ..................................................96
4.5 AM Step 4: General Inspections and SHE .......................................96
4.5.1 Incorporating Real-Life Safety Examples into AM
Training ..................................................................................97
4.6 AM Step 5: Autonomous Inspection and SHE .................................97
4.6.1 S Points (Safety or SHE Points) .............................................98
4.6.2 SHE Mistake-Proofing or Poka Yoke .....................................99
4.7 AM Step 6: Standardization and SHE ..............................................99
4.7.1 SHE Standards .....................................................................100
4.7.2 Zero Accident and Zero Incident Lines ..............................100
4.8 AM Step 7: All-Out AM Management and SHE .............................100
4.8.1 Comprehensive SHE Inspection and Auditing ...................100
Endnotes ..................................................................................................103
5  Integrating SHE, Planned Maintenance, and
EarlyManagement ...................................................................105
5.1 Rationale behind the Integration of
PlannedMaintenanceandSHE ......................................................105
5.2 Safety Permit Systems .....................................................................106
Contents ◾  ix
5.3 Planned Maintenance Support for AM and SHE ...........................107
5.4 PM Safety Checklists....................................................................... 110
5.5 Early Management and SHE........................................................... 111
5.6 Hazard and Operability Reviews ................................................... 111
5.7 FMEA and Start-Up Checklists ....................................................... 112
5.8 306090 Day Reviews .................................................................. 116
Endnotes .................................................................................................. 116
6  Focused Improvement, Training and Education, and SHE ...... 117
6.1 Rationale behind Integrating FocusedImprovement and SHE .... 117
6.2 SHE Kaizens ...................................................................................118
6.3 5S for SHE/6S: Condition-Based Kaizens ......................................122
6.4 People-Centered Safety: Behavior-Based Kaizens ........................123
6.5 Integrating SHE into the Training and Education Pillar ................125
6.6 Shu Ha Ri ........................................................................................125
6.7 One-Point Lessons (OPLs) ..............................................................127
6.8 SHE Training Plan and Kaizen Gym .............................................128
Endnotes ..................................................................................................134
7  SHE Pillar Activities ................................................................135
7.1 SHE and Lean .................................................................................135
7.2 SHE Pillar Master Plan and SHE Management Systems ................136
7.3 SHE Pillar Self-Assessment ............................................................. 145
7.4 SHE Control Charting .....................................................................148
7.5 SHE Visual Mapping and Charting ................................................154
7.5.1 Dot Distribution Mapping ...................................................154
7.5.2 Body Mapping .....................................................................154
7.5.3 Fishbone Mapping ...............................................................156
7.5.4 Discharge Mapping ..............................................................158
7.5.5 Process Flow Mapping ........................................................ 159
7.5.6 Contour Mapping .................................................................160
7.6 SHE Pillar Activity Board ............................................................... 162
Endnotes ..................................................................................................165
8  Lean and Green: Applying Lean to the Environment .............. 167
8.1 Lean and Environmental Sustainability ......................................... 167
8.2 The Lean and Green Sustainability Roadmap ............................... 172
8.2.1 Phase 1: Recognize .............................................................. 173
8.2.2 Phase 2: Visualize ................................................................ 174
8.2.3 Phase 3: Organize................................................................ 174
8.2.4 Phase 4: Strategize ............................................................... 175
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8.2.5 Phase 5: Conceptualize ....................................................... 175
8.2.6 Phase 6: Prioritize ................................................................175
8.2.7 Phase 7: Operationalize ....................................................... 176
8.2.8 Phase 8: Synthesize ............................................................. 176
8.2.9 Phase 9: Integrate ................................................................ 176
8.2.10 Phase 10: Synergize .............................................................177
8.3 Applying Value Stream Mapping to the Environment ..................177
8.4 Applying Visual Controls to the Environment ..............................181
8.5 Lean and Energy ............................................................................182
Endnotes ..................................................................................................185
Bibliography ...................................................................................187

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