igus Inc. | Excellence in Safety Performance & Records
When leaders at igus Inc. decided to implement safety defibrillators and offer CPR classes to employees, they had no idea there would be such an immediate life-saving effect.
“To our surprise, 25 percent of the workforce signed up for the training,” said Gerry Fournier, operations manager. “But the most remarkable thing was, just a little while after, one of our employees, coming into work one day, saw a person in distress in the snow. He stopped and performed CPR. Because he had just done that training, he felt comfortable doing so.”
According to Fournier, the medics said it saved the man’s life.
“We’re very proud of him,” he said.
Of course, thinking about safety is just part of the job at igus, the North American production and distribution facility for the larger igus GmbH in Germany. The company specializes in engineered plastics and parts such as ball bearings and chains and cables.
“Safety is part of our [daily operation],” said Lead Supervisor Mark Leland, a 25-year igus employee. “Team leaders and supervisors mix on the floor with employees, so there’s an awareness that helps to promote a safe environment. We have daily team meetings to review any issues and concerns.”
The team at igus also created an iPad application that allows all employees to participate in workplace processes and safety, the goal being to get direct information and input from the warehouse floor.
“You have to have a tool or mechanism in place for employees,” said Fournier. “They don’t want to fill out paperwork. So, we developed our own app you can take notes of safety hazards.”
“Any employee can document something they see,” said Leland. “They take a picture, send it through email and we put together a team to take care of the issue and prevent it from happening again.”
For the last 13 months approximately 60 items were reported for consideration. Only three were safety-related. And the company’s insurance carrier reports a very low percentage of loss. Even better, the iPad app allows all employees to take ownership of safety and improvement to the company process. It’s important for all employees to understand the ramifications of even a small mistake.
Something as seemingly benign as nudging a product rack can compromise the whole system, possibly sending items cascading across the floor. It nearly happened once, but with immediate attention given to the problem, a larger accident was prevented.
“No small incident is too small to tell us,” said Fournier. “Just let us know. You’re not going to get fired.”
Ergonomics is another big component of the warehouse and office design, according to Leland.
Lift trucks are specifically designed to minimize impacts of heavy hauls and have enclosed cabins to eliminate fall hazards. Tables and chairs are adjustable to allow for proper work height.
“We want employees to stay in their comfort zone to allow for less fatigue and fewer strains to occur,” said Leland.
He said the floor is also designed with tracks to keep lift trucks in the right place, and a system where the right equipment is in the right spot at the right time, eliminating the potential for employees to use the wrong tools for a task.
It certainly doesn’t hurt to be part of the safety team; in fact, it pays off in many ways. Once a month, the Idea of the Month is awarded to the employee whose idea had the most impact.
The emphasis on safety is good for the customer, too. Many igus products are designed to be a better alternative to traditional bronze parts that are often covered in oil and slippery.
“Our products are oil-free and clean, there’s no maintenance later on. It’s a big advantage for us in the marketplace,” said Fournier.
