Is is possible to increase productivity and safety at the same time?
Is is possible to increase productivity and safety at the same time?
Workplace safety is a topic that resonates across all industries. And rightly so. Employees have the right to work in an environment where risks of injury and health hazards are minimized. On the other hand, every company faces pressure for productivity and efficiency. At first glance, these two goals – safety and productivity – may seem to be an opposite. However, the principles of Lean Manufacturing show us that this need not be the case. On the contrary, well-applied Lean can help improve safety and productivity at the same time.
Lean as a basis for harmony between efficiency and safety
Lean Manufacturing is an approach that focuses on eliminating waste and creating value for the customer with minimal resources. When we hear „waste“, many of us think of excess inventory, unnecessary movement or waiting in production processes. But what few people consider is that waste can have a direct impact on safety.
Imagine, for example, a work environment where storage areas are crowded and employees have to move between obstacles. Such an environment increases the risk of falls, collisions and other accidents. By eliminating this type of waste – for example, by better organizing the workspace according to 5S principles – we not only speed up work, but also create a safer environment.
Key Lean tools for improving safety
There are several Lean tools that have a direct impact on workplace safety. Here are a few examples:
- 5S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke): This tool is often considered the foundation of the Lean approach. A clearly organized, clean and tidy work environment reduces the risk of accidents while increasing efficiency. When employees don’t have to search for tools or avoid hazards, they work faster and with less chance of injury.
- Kaizen (Continuous Improvement): Engaging employees in continuously finding and eliminating hazards in the workplace is the key to success. Kaizen fosters a culture where employees are actively involved in process improvement, resulting in innovations not only in productivity but also in safety.
- Standardization of work: Clearly defined and followed work procedures minimize the room for errors that could lead to accidents. Standardisation also helps in identifying potential risks and eliminating them quickly.
- Poka-Yoke (avoiding mistakes): This concept involves designing processes and equipment to make it impossible to make a mistake. For example, safety locks on machines or control mechanisms that highlight potential problems minimize the risk of accidents.
Case study: Lean and safety in practice
When I was Regional Lean Manager for 8 European plants, safety was our priority. In one plant (the highest fire risk), we set up evacuation zones within 5S so that in the event of an evacuation, every worker knew which zone to go to and we were able to quickly count if anyone was missing. This paid off when we had a real fire, 6 fire brigades arrived and the CO2 release was activated.
Culture change is key
Improving safety and productivity is not just about tools, it’s also about changing the mindset. Companies that implement Lean must create a culture where safety is not disconnected from productivity, but part of it. This means engaging employees, communicating with them, listening to their concerns and incorporating their input into the changes.
Conclusion
Lean Manufacturing clearly shows that productivity and safety can be improved simultaneously. When we focus on eliminating waste, we create processes that are not only more efficient but also safer. Investing in a Lean approach pays off for companies in the way of fewer injuries, higher employee morale, and improved overall results.
As someone who lives Lean, I believe that any company can achieve this harmony – it is just about to apply proven principles. Safety and productivity are not opposites; they are two sides of the same coin.
And Lean, done right, is the key to connecting them.