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JJ Culture of Safety Maturity Assessment FY23Q4
JJ Culture of Safety Maturity Assessment FY23Q4
2 3
1 Extensive record of application &
Can apply with help with limited Can consistently apply the skill
Description Can talk about it but has little or no results over an extended time period
experience putting the skill to use in without help with a growing track
practical experince applying the skill with ability to teach & develop
the path of the work record of results achieved
capability in others
Skills Definition
1. Can explain the different steps in 1. Teaches the different steps in the
1. Can explain the different steps in
the Engagement model. Engagement model.
the Engagement model and explain
the key principles in each step.
2. Followed engagement model in an 2. Enforces & applies model for all
actual lean effort with help. (provide Lean engagements. (provide
2.Applies engagement model for all
supporting documentation) supporting documentation)
1. Has been Instructed on the Lean Lean engagements (provide
Be versed in the different components of the Nike Lean Engagement
Engagement Model and read the supporting documentation)
Model and be able to teach them, including our Lean assessment. 3. Applies standard templates and 3. Teaches how to use the standard
1. Lean 2.0 (Lean Operating 2. Lean 2.0 (Lean Engagement Model, Lean Playbook.
Global Lean has standardized key tools and templates for when forms with help for all Lean templates and forms Enforces and
System) Assessments, Standard 3. Applies standard templates and
coaches engage in the business. All levels applying lean should know engagements. (Provide supporting uses templates for all Lean
Templates/Forms) 2. Has been instructed on the forms for all Lean engagements.
what the templates are, where they are located, when to use them, documentation) engagements. (Provide supporting
Target: 75% completion standard templates for Lean and (Provide supporting documentation)
and be able to explain their intent and how to use them. documentation)
where they are located.
4. Provides feedback on issues/
4. Develops and improves Lean
opportunities to improve on 4. Develops and improves Lean
templates.
templates templates to drive best practices.
5. Has led or co-led a Lean
5. Has participated in a Lean 5. Led and instructed coaches in the
Assessment and scoring event.
Assessment with a Lean Master. Lean assessment and scoring process.
1. Employee has been trained on A3 1. Employee can apply, with help, A3,
thinking and PDCA. PDCA, Improvement Kata, and
DMAIC.
2. Employee can describe what A3
thinking is and the steps of PDCA 2. Understands the key
1 Employee teaches the concepts in
3. Understands what Improvement characteristics and can tell when and 1. Employee can successfully apply
training or mentoring sessions.
Kata is and how it utilizes PDCA for where to use this thinking. A3 thinking and Kata/PDCA in their
A3 Thinking and PDCA are the most important principles at Nike to continuous improvement. lean engagements.
2. Has 2 site examples of the use of
drive continuous improvement and a standard way of applying Lean. 4. Understand the DMAIC concept 3. Write a Reflection summary of the
3. A3 Problem Solving (PDCA Thinking & A3/PDCA/Improvement Kata from
Improvement Kata and DMAIC are also critical in driving continuous and potential benefits use of A3/PDCA/Improvement Kata. 2. Provide supporting documentation
Continuous Improvement Process different events to use as a training
improvement. To solve problems, there is a need to have a standard of the use of A3/PDCA/Kata in a Lean
Methodology) reference and to show aptitude in
set of tools for Work flow analysis, data collection, identifying root 1. Employee has been exposed to 1. Employee had helped in using the Effort.
these methods.
cause and evaluating variation tools for problem solving and root utilizing 4 of 5 techniques with a
cause analysis: Master coach: 3. Has been a participant in an
3. Is a DMAIC resource for Nike and
a. 5 Whys a. 5 Whys DMAIC engagement.
can teach and facilitate as needed.
b. Fishbone (5Ms) b. Fishbone (5Ms)
c. Failure Mode & Effect Analysis c. Failure Mode & Effect Analysis
(FMEA) (FMEA)
d. Problem Solving Storyboards d. Problem Solving Storyboards
e. TAKT time analysis e. TAKT time analysis
2. Lean Fundamentals
(Training)
1. Completed Global Lean 1. For a cross functional process or 1. For either manufacturing or
1. Has created, with help, a process
Fundamentals training. entire distribution/manufacturing transactional problem, run a mapping
map (swim lanes), and a Value
2. Can describe the differences and process, create a comprehensive session with a team to build a VSM of
stream map of a simple process.
benefits between a flow value stream map or process map. their process.
7. Tools - Mapping (VSM, Process, Applying the various data and analysis tools in a real engagement to 2. Reviewed process map and VSM
chart/spaghetti diagram, process 2. Review with Lean Master and get 2. Review and provided feedback on
Spaghetti) show proficiency and successful use of them with a Lean Master for feedback and
map with data, & Value Stream Map. signoff of completeness for business a Lean Coach or Specialist's maps for
reflection.
3. Can explain why a process map or problem. completeness and accuracy.
2. Provide examples of final process
VSM is a critical tool for process 3. Capture an example in your Lean 3. Approved to train Lean Coaches
map and VSM in their Lean Journals.
improvement Journal. and Specialists on mapping.
1. Completed Global Lean 1. Identify examples of replication 1. Facilitate Lean event that will be
1. Facilitate a cross functional
Fundamentals training. applied at Nike. replicated. Build replication
The process of repeating the process improvements from one process replication event. Identify differences
2. Be explain the SCORE step to 2. With help, facilitate a replication documentation and preparation
11. Replication to another similar process or area to benefit from the existing process from original and implement process
sustain and replicate solution to event. Provide example in Lean requirements.
changes. for new area. Provide documentation
similar areas that can leverage the Journal of effort, changes, and 2. Co-Lead Lean Specialist or Lean
in Lean Journal.
new process steps. results. Coach to build their replication skills.
Secondary Assessment Based on Interviews and Lean Journal, Assess based on competency (1 to 10)
Criteria
NAME OF ASSESSOR: Tria, Zauzan, Lista, Suryani, Diah OVERALL ASSESSMENT RESULTS TOTAL SCORE 74.07%
Objectives: Creating a Safety Culture:
- Evaluate strengths and opportunities for location's Culture of Safety
- Prioritize focus areas and resources
CONTACT NAMES: Tria Agustina - Identify needs for support
Leadership Safety Management Risk Assessment Workforce Planning Skilled Workforce
Summary:
Strengths:
LAST UPDATE: May, 15-20 2023 Strengths: Strategy driven by Corporate, Headquarters support for Culture of Safety, leadership engagement safety activities through shopfloor activities and communication process. safety documentation are regularly reviewed, internal audit and safety
performance evaluation (KPI), safety into performance evaluation. Resourcing of HSE team and development of HSE team members
Top opportunities:
Resource to support works (skill level) to strengthen deployment of safety culture, need to incresing completion for minor and major finding, programs of related Department are aligned with safety culture.
CULTURE OF SAFETY ATTRIBUTE CULTURE OF SAFETY ACTIVTY ASSESSMENT COMMENTARY, Also include A-D-R Approach SUPPORTING DOCUMENTATION REVIEWED SCORE TOTAL POSSIBLE
- Regularly conduct biannual integrated internal audit (ISO 14001, OHSAS 18001, SMK3 and SLCP), annual audit - HSE Committee Organization
to material vendor, monthly HSE inspection and review safety performance through daily activities (DOR) - HSE Monthly inspection
- HSE Weekly report
- Regulation update
C
R
I Factory or Factory Group does have a formal safety policy statement (Deployment) :
T - Senior management or HoD involves to create the Factory vision, HS vision and HS goal.
I Factory or Factory Group has a written and formal safety policy statement
- Deploy our HS goals by leadership, mid-level and employees. - CS Vision
C that includes the principles & objectives as outlined by the ILO Safety
A - Develop HSE policy with employee representatives - HS Goal 5 5
Management System Model
L - HS goal implementation by Policy Deployment board, Accident meeting, HSE committee, Leadership meeting - HSE Policy
Critical Enablers (NSC and Management Review)
E
N - Socialize HS Goal through training, posting RSM board, magazine, campaign, etc.
A
B
L
E
R Factory has a competent person to oversee the HSE/Culture of Safety
S Program. A Competent Person who is reponsible for developing
corporate/factory CoS annual plan and budget and resource requirements - Factory has Dedicated HS leader in managemnt level and compotent HS team to oversease the HSE / Culture
to implement a long term strategy. - HS organizational structure
of Safety program
- Occupational Safety and Health Expert
- Has HS long term & annual plan to control and monitoring HS program
Certificate
- Has HS budget plan to support HS activity 5 5
- HS annual & long term plan
- Upgrading skill for HSE member based on training need analysis
- HS budget plan
- Has Certified HS competent person
- HS training lead analysis
- Has Succession plan based on criteria
18 5
Safety mission/vision
1. Management commitment visibly demonstrated thru positive behaviors, HS investment and time to achieve
HS goals.
-HS Long term & annual plan and MoM
a. 3-5 year strategic plan based on HS vision.
-2022 HS KPI target
b. HS strategy is completely integrated into the business processes of the organization.
-HS organization
c. Post HS goals on each workshop
-HS budget tracking
2. Strong HS Leadership Organization (Have a dedicated HS senior leadership, 8 Safety Representative at
-AM-PM Machine 6 10
workshop)
- Risk Assessment Procedure
3. All levels of employees are aware of HS standards & requirements
- NEI and safe machine procedure
4. Review HSE Inspection & Audit Internal
- Communication regarding safe machine
5. Review KPI monitoring on Daily Operational Review & Policy Deployment
requirement for new machine
6. HS budget allocation is provided
7. Safe machine based machine procurement
- CS Vision
- Annual Policy
- Factory has HS startegy goal that integrated in the Hoshin Kanri process. - PD KPI
- Factory has annual safety KPI that singed by leadership - HS long term & annual plan
- Has detail budget to support safety activity implementation - Implement ISO 45001 management system 7 10
- HS KPI review by DOR, PD, Accident meeting (if any case), HSE committee, Leadership meeting, etc -HS activity report (WSF, competition, campaign
- Factory has NEI procedure for assessment new technology & recognition)
- NEI Procedure
L
- Result of NEI (last NEI for OPC machine)
E
A
D
E
R
S Leader standard work (safety)
H
I Leadership 1. Safety point include on the leader standard work. Leaders do daily review meeting to share, escalate and
1. Leader Standard Worksheet for TL, GL, VSM”
P Engagement and define the countermeasure.
2. Detail of Jobdesc for Supporting area
Accountability 2. Interactive communication on :
A 3. PD Meeting report
C a. Managements and workers participation in HSE committee meeting. 7 10
T 4. Safety Talk by Leader
b. Police Deployment Meeting
I 5. Safety Gemba by Management
V e. National steering committee
6. HS Campaign by Leader
I 3. Factory needs to implement LSW for leadership and Korean coach after TL/GL and VSM
T
I
E
S Leader visibility/engagement with workers
1. Safety review in :
a. Leader standard work
b. Policy Deployment
- LSW, DOR, PD KPI.
c. Safety gemba (P2K3)
- Management Review
2. Active participation with others (Factories, government, etc.) on HS activities, i.e Best practice sharing with
- CSG RSM Summit 8 10
government and other factories
- EWB survey result on 2022 as behaviors and
3. Evidence of CSR documents of local community and school
attitudes towards safety
4. Biannual Management Review
5. Annual CSG SMS Summit
6. Factory conducts an EWB survey of employees related HS
1. Aligned CS vision with performance evaluation; performance evaluation is continuously improved ”Form Performance Evaluation”
2. Safety included in performance evaluation for all level '- PE Procedure 7 10
3. Performance Evaluation of Employee as one of Promotion Requirements - PE Form
4. The process of Performance Evaluation is formal and documented - Safety point include to performance evaluation
51 70
Safety Management
System and Metrics 1. Factory fully tracks leading indicators (nearmiss), lagging indicator (labor accident), Job Hazard Analysis and
preventive actions are taken to reduce risks.
- HS KPI on PD and DOR.
Safety metrics / KPI's/ Data Management Systems 2. Collect HS data on centralized system. Performance data is easily accessible to all personnel. Review : Daily 8 10
- Management review
Operational Review (DOR), Policy Deployment board, Accident meeting, HSE committee.
3. Biannual Management Review
SWS
1. Safety is incorporated in all jobs activities in the company (including SWS, SOP with content related to safety,
AM cheklist
TPM activities).
SOP
Safety is included in standard work 2. Training Gold which is included in the training curriculum (there is SWS material). 7 10
Job Description
3. Involving employees in making standard work (SWS) and reviewed by HS team.
Safety Kaizen report
P 4. Peer Coaching Program for HS Team
Report of Peer Coaching Activity
R
O 31 40
C
E 1. Procedure for risk assessments and job hazard analysis, and risks control.
S -Risk assessment procedure
2. Hazard identify and risks assessment process in place
- Safe machine matrix.
S Comprehensive Risk Assessment and Analysis
3. Deployment to all employees
- Risk assessment machine 6 10
4. Implement risk assessment and analysis for facility (machine risk assessment, when have layout changes,
- HIRA by Process
A remediation of risks) and priority to make countermeasure for improvement
- JHA by process
C HS analysis point in cooperate to Hoshin Kanri Process
T
I
V
I
T 1. HS’s concerns are defined in aspect impact identification procedure base on OHSAS 18001 and “Design,
-Management of Change Procedure
I Engineering and Management of Change” guideline
-MoC report
Risk Assessment process for evaluating major facility changes 2. Update facility risks following changes to facility but not consistently applied. need consistency of 7 10
E management of change implementation
-New equipments procedure
S -New equipments introduction
3. Continuous Improving & control program together with Risk Assessment & Risk Control procedure
4. Review assessment result, analysis and priority to make action plan - Safe machine matrix
5. Continous improvement for machine risk assessment process
Risk Assessment and
Remediation
1. Risk remediation process is applied facility and includes worker input and feedback - Hazard Identification and Risk Assessment
2. Daily check and tracking report for remediation risks - Objective, Target, Plan related to HS
3. Risks assessment and analysis to make improvement plan & tracking - Improvement HS cases, ex : accident, fire
Remediation of risks 4. Factory had periodic review HS performance data : sharing performance data through Daily Operational incident
8 10
Review (DOR), weekly policy meeting, monthly leadership meeting -Management Action Plan (OTP Sheet)
5. Hazard Identification by all level of employess and Near Miss reporting.
Risk Assessment and
Remediation
Process to correct hazards identified by hazards and unsafe behaviors in place (nearmiss, sugesstion system) -Nearmiss process (including report and follow
Near-miss finding report from line employees and tracking weekly base up)
All near-miss and safety issues with corrective action tracking records on IT system - Suggestion System
Process to correct hazards and unsafe behaviors identified by workers Kaizen policy including safety suggestions by all employee levels -MoM HSE Meeting 8 10
HSE committee meeting regularly discuss HSE issues -Report issue by case
HSE meeting with related departemen (if any case) - CAR of nearmiss by priotizing
- Grievence system related safety
42 60
Process for recruiting/hiring inclusive of safety based the safety senstivity
of position.
- Recruitment Flow Chart
HRMAT DEPENDENT - Recruitment Procedure
Recruiting/hiring procedure in place
-Interviewer certificate
Job descriptions exist for all positions with clear description of R&R & required skills and competencies
- Provide Job des for HS person
Using safety points in JD and list of interview to determine positions for hiring individuals
-Provide Job des for all level (safety included) 9 10
Clear requirement for hiring safety positions (at least have safety qualifications)
- List of interview related safety
Job vacancy information at Disnaker, all of HR board in each Plant, LinkedIn
- Job vacancy posting (Safety point include to
Had certified for HR recruitment staff by third party
qualification)
35 50
Factory or Factory Group does not Factory or factory group has a Factory has a written and formal safety
have a formal safety policy written safety policy statement policy statement which is aligned with
Factory or Factory Group has a written and formal statement but is not aligned with the ILO ILO Safety Management System Model. YES!
safety policy statement that includes the Safety Management System Leadership commitment is present, but Factory or Factory Group does have a formal safety policy statement which is
principles & objectives as outlined by the ILO approach policy is not affectively communicated committed by the leadership and broadly communicated in the organization
Safety Management System Model* throughout the organization.
Input Maturity Level 5
Safety is fully integrated in the Hoshin Kanri Safety in not considered in the Safety has just recently been Safety is fully integrated in the Hoshin Safety is fully integrated in the Hoshin Safety is fully integrated in the Hoshin Kanri
LEADERSHIP process or the factory has a business integrated Hoshin Kanri Process or only included in the Hoshin process, Kanri process or the factory has a Kanri process and Safety Goals and process and there is a history of delivering
safety management system that aligns with the included ad hoc after safety issues and the process for including business integrated a safety Objectives focus on continuous value to the business. Metrics are owned by
ILO Safety Management System Model* or arise. safety is being developed management system that aligns with improvement. Hoshin process defines the business and could include: Risks,
OHSAS 18001 the ILO Safety Management System specific metrics and KPI's. (i.e. Risk downtime, production efficiency, quick
There is no safety management Model* or OHSAS 18001 reduction, adaptability to new change over, integration of new technology,
system technology and product change over, behavior based metrics.
production delays due to safety are
predicted and prevented)
No Safety compliance program in Not all compliance areas are Compliance programs cover all Compliance programs include Compliance programs are reviewed during
place OR covered by the compliance applicable CLS and local laws. continuous improvement as a key the Hoshin Kanri process, performance
program. metric for peformance. standards go above and beyond legal and
Limited safety compliance Minor non-compliance findings during CLS requirements, and factory consistently
programs in place. Programs may Functional programs are up to formal self assessment and/or corporate Some behavior based activitites are meets performance metrics.
be out of date. date (i.e LO/TO, Hearing audit program are used to identify gaps included in compliance programs.
Conservation, HAZ COM, etc.) in program. Compliance program include behavior based
Factory is not monitoring Factory actively monitors changes to activities.
regulations. Little to no self- There is a formal self- existing regulations and incorporates
assessment or corporate audit assessment and/or corporate pending legislation in compliance There is an internal system for continuoulsy
PROCESS Safety compliance program in place program. audit program and only minor programs. monitoring compliance and non-compliance,
compliance findings were and corrective action is priortized and
discovered. Factory is consistently meeting countermeasures implemented timely.
continuous improvement compliance
targets
8
Safety mission/vision No Safety mission/vision or Written mission/vision, senior Documented, clear safety Safety is integrated as part of the Safety is integrated as part of the
level awareness. May be some mission/vision, reviewed annually, Corporate Mission and Vision Corporate Mission and Vision, and visibly
Safety Mission is written, but what out of date, or not clearly signed by senior management/senior drives business decisions, including safety
general direction known, not defined. management ownership, posted in strategy, budgets, resources, and
documented, little senior level facilities. organizational structure
awareness
Multi-year safety strategy/priorities No written safety strategy, High level safety goals and Long term and annual safety strategy is Safety Goals and Objectives Execution of safety strategy delivers value
reacting to issues and incidents objectives through Hoshin Konrideveloped as part of the Hoshin Konri consistently exceeded. to the business. Metrics are owned by the
process or strategy deployment process or strategy deployment process. Leadership has defined how the business and could include: Risks,
Random objectives or goals, process. Focused priorities forThis includes documented safety strategy delivers business downtime, production efficiency, quick
primarily associated with current year. goals/objectives, KPI's, budget and value through specific metrics and change over, integration of new
compliance resourcing KPI's. (i.e. Risk reduction, technology
6
Not a clear HSE Organization but adaptability to new technology
No HSE Organizational Strategy Individuals in place to support HS Sr management is engage in driving and product change over,
successful execution of the strategy and production delays due to safety
Budget and resourcing limited for Budget and resourcing provided engagement is well documented are predicted and prevented)
safety activities but not clearly linked to safety
objectives. Some examples of Clear HSE Organizational Structure, with
success in executing objectives. senior level individual responsible for
HSE strategy
Safety is fully integrated in the Safety in not considered in the Safety has just recently been Safety is fully integrated in the Hoshin Safety is fully integrated in the Safety is fully integrated in the Hoshin
Hoshin Kanri process Hoshin Kanri Process or only included in the Hoshin process, Kanri process or the factory has a Hoshin Kanri process and Safety Kanri process and there is a history of
included ad hoc after safety issues and the process for including business integrated a safety Goals and Objectives focus on delivering value to the business. Metrics
arise. safety is being developed management system that aligns with continuous improvement. Hosin are owned by the business and could
the ILO Safety Management System process defines specific metrics include: Risks, downtime, production
There is no safety management Model* or OHSAS 18001 and KPI's. (i.e. Risk reduction, efficiency, quick change over, integration
7
system adaptability to new technology of new technology, behavior based
and product change over, metrics.
production delays due to safety
are predicted and prevented)
Leadership
Engagement
and Leader standard work (safety) No leader standard work (safety) Leader safety standard work is Leader safety standard work is Leader standard work drives safe Leader standard work drives safe behaviors
Accountability
7
identified -- examples include: identified for all levels of leadership. behaviors and attitudes within the and attitudes within the entire
Leaders generally aware of safety safety topics as part of meetings, Includes safety topics as part of factory, and is observed on the organization, from worker to supervisor to
issues, but not documented gemba walks, reviews. May not meetings, gemba walks, reviews. factory floor GM to Executive
evidence of leader safety standard be fully implemented. Most Evidence of implementation.
work. Leader safety activities may leaders included. Factory uses EWB results are used as
be adhoc and inconsistent. indicators of Leader visibility and
engagement.
Leader visibility/engagement with Limited or no leader visibility or Leadership engagement is Genuine collaboration between leaders Engage leaders drive worker Safety issues are routinely and consistenly
workers engagement on safety issues. observed in several areas , but not and workers is consistently observed behavior as evidenced by a safety identified and resolved collaboratively by
consistent. Leaders follow up and documented, including leadership escalation process that involves workers and management throughout the
8
Leaders inconsistently react to and react when safety issues accountability for follow up on safety both workers and leaders, is facility and improvements are
safety issues. occur. issues identified by workers, injuries, effectively implemented, and documented.
incidents, and trends several examples are
Leaders directive in their approach A process is in place for workers documented. Factory uses EWB results (or similar)as
to safety and workers do what to identify, report and escalate indicators of Leader visibility and
they are told safety issues, but the practice is engagement.
inconsistent
Leadership review process for safety No leadership review process for Leadership is aware and updated A periodic review of the culture of Senior Leadership sets internal The culture of safety is immediately visible
8
system safety system or on safety system. Annual review safety is conducted with senior metrics and KPI's to measure the throughout the factory, evidenced by
may be conducted of safety leadership is documented, with culture of safety systems and worker and leadership behaviors and
Limited leadership awareness on system; may not include all actionable outcomes. worker and leadership behaviors attitudes towards safety (EWB).
safety system and components. components. and attitudes.
Leadership continuously monitors safety
processes, and improvements are
documented.
Safety included in performance Safety not included in annual Safety included in performance of Safety is included and documented in Safety is included and EWB is used as a tool to assess leader
7
evaluation performance evaluation most factory workers. performance evaluation of all levels, documented in performance safety performance, and is included in
Documented. May not included including management. The process is evaluation of all levels, and performance evaluation of management
Safety included in performance of specific behaviors. formal and documented. specific safety behaviors and and senior leaders.
few workers. Inconsistent. Very attitudes of the factory are used
high level -- may not be detailed. May not include behaviors and attitudes as metrics to assess peformance.
May not be formal and
documented.
Culture of Safety Activity 0 3 5 7 10 Maturity Score
Attribute
(Input)
Process for recruiting/hiring inclusive of safety Safety not considered in Recruiting activities occur on a Candidate screening and selection are Job descriptions exist for all Candidate screening is based job descriptions as well as
based the safety senstivity of position. recruiting/hiring reactive basis to meet functional based on the minimum skill level and positions (operators, T/L&G/L, staff, safety best practices learned from past experience,
department's short-term needs. safety knowledge requirements management) with clear description which help to identify the most suitable candidates.
contained in job descriptions for of roles and responsibilities,
Job descriptions are developed majority of positions. required skills and competencies. Evidence of safety evaluation is documented.
and managed by individual
functional departments, not a Factory provides training to HR staff Safety sensitive positions require
central HR function. Limited safety responsible for recruiting and selection certification and/or have safety
9
inclusion in job descriptions. processes. qualifications.
Safety Training and Development Plan No safety/training development Limited training conducted, 1 to 2 A formal training curriculum exists and Training is consistently conducted There is a formal learning system with designated
plans safety training topics. Conduct a meets legal requirement Include some and documented. Learning through trainers, mentoring programs and external learning
new hire orientation and general specific training for job hazards. peer coaching is part of the training opportunities (university courses) paid by the company.
Team member has no knowledge safety training., but no long term Evidence of training is documented. curriculum.
of applicable safety standards strategy. Inconsistent
related to their job. No process in documentation of training. Team members are knowledgeable of All team members are
place to verify knowledge or high risk safety standards. There may knowledgeable of applicable safety All team members are knowledgeable of applicable
awareness. Team members not be minor knowledge gaps. standards. safety standards and have the skills and knowledge to
knowledgeable of applicable train their peers.
safety standards related to their Formal process (ie, test, performance Non-technical safety training is
9
jobs. Informal process in place to review) in place to verify knowledge or included in the curriculum, and WSF program is consistently applied in whole factory.
verify knowledge or awareness. awareness. includes how to participate in safety Training effectiveness is periodically assessed.
initiaves, problem solving, general
Team Leader and Group leader WSF Program is in plan. WSF Trainers health, and behavior observations.
may have awareness. are certificated. Trainings for facilitators
are in progress. WSF Program is in place. Facilitators
have yearly training session plans
based on prioritised HSE topics.
Appropriate human resources to support work** No HSE staff to support work or ad No evaluation of HSE staff needs, Hoshin Kanri process is in place to CoS resources in place and Resources are in place. Retention and succession plans
hoc support through another but a full time HSE person is on evaluate CoS staffing needs, but onboarded. Little track record of are in place. Turnover, when they occur, does not
Workforce Planning Strategy level, program management level, department staff. there may be some gaps in turnover. create a gap in the Culture of Safety program.
(HSE Organization) Production line level headcount .
Team members are engage in safety A long track record of team members engagement in
activites throughout the factory. safety kaizens and worker initiated improvements.
8
Retention and HSE team member career No retention or career Career development Career development opportunities are Career development opportunities Factory has a formal procedure to manage career
development Linked to HR organization activities development plan for HSE team opportunities are very limited for available for limited categories of HSE are available for all HSE team development for HSE Team members, which is linked to
members HSE team members and Team members, such as high potential members, including operators, a performance evaluation system.
management staff, even for employees. T/L&G/L, staff and management.
workers with high potential. Job rotation, mentoring, on-the-job training and off-job
Management training and career Factory has a formal educational training are widely used to support career
There are isolated examples of development programs exist, is and program to support operator career development.
workers promoted from within. there are a few examples of workers development, such as night school.
8
promoted from within. A large proportion of managers, T/L&G/L, and HSE staff
Sevaral examples of managers and are promoted from within. Many of them are promoted
T/L&G/L are promoted from the from the worker level.
worker level through career
development programs.
Succession planning for HSE organization No succession plan for HSE team Limited succession plans for team Succession planning is conducted by HR partners with leadership and HR plays a leading role in factory-wide succession
members members. Critical HSE team factory leadership and functional managers during Hoshin Kanri planning, including key CoS staff positions. HR assesses
members not identified. managers (not an HR function), but process to identify an inventory of talent supply from internal and external sources.
there is no standard procedure or key jobs that support the Culture of
documentation. Safety program . CoS individuals with high potential are identified and HR
7
partners with leadership and managers to create
There exist clear criteria for individual career plans.
successors of the key CoS jobs.
Procedures exist to identify and
develop high potential employees.
Comprehensive Risk Assessment and Analysis** No comprehensive risk Facility risk assessment exists. Comprehensive facility risk assessment Buisness continuity and Business continuity and Contingency plans
assessment in place May have significant gaps, but covers anticipated risks to facility with contingency plans are in place are in place and fully resourced
Guidance for facility/operational risks major risks identified few gaps but not resourced in case of an
https://www.dir.ca.gov/dosh/etools/09-031/ Risks identified ad hoc or emergengy Risk assesssments and analys are done
HazAssessCheck.pdf retroactively after and incident. Assessments may be out of date Assessments are up to date and continuously and part of the safety culture.
or incomplete. reviewed at least annually. Annual risk analysis identifies
6
Guidance for external risks to the Factory No inclusion of risk analysis into program gaps, and is fully
http://www.fema.gov/media-library-data/20130726-1530- strategy and annual objectives Risk analysis is disjointed from Process in place to incorporate risk embedded into the Hoshin Kanri Documentation verifies that risk anaylsis
20490-5739/fema433.pdf strategy and annual objectives analysis into Hoshin Kanri process, process. has consistently been integrated in Hoshin
including strategy development and Kanri for multiple years.
annual objectives.
Risk Assessment process for evaluating major facility No risk assessment process to When facility changes occurs, risk Process in place to update facility risks Process in place and consistently Process in place, and documentation of all
changes, including changes to manufacturing process that address changes assessments are inconsistently following changes to facility. applied. facility changes that impacts risk, including
requires building structural enhancements. completed. updated engineering drawings, are
7
http://www.iitk.ac.in/nicee/wcee/article/2826.pdf Documentation of change is available for review.
inconsistent.
Machine risk assessment process No machine risk assessment Limited machine risk assessments Machine risk process in place, Machine risk assessment process Machine risk assessment process in place,
process conducted. Not consistent inconsistent completion of risk in place, completed for most completed for all machine types in factory
process. assessments. machine types in factory and up- and up-to-date.
to-date.
7
Plan to complete remaining risk All machines are in compliance with Nike's
assessment is in place, and on target for Targets for machine related machine safety standards and Zero
completion. incidents are established. machine related injuries have occurred
within the past 3 years
Remediation of risks*** No remediation of risks identified Some documented process in Process in place to remediate Risk remediation process is There is a formal system to track risks and
place to remediate risks, unacceptable risks, all risks remediated applied factility wide and includes remediation. The system is used to
Risk Assessment Risk are not prioritized and inconsistent remediation of risks. to an acceptable level. The process is worker input and feedback. identify trends and areas of improvement.
remediation is ad hoc. implemented in high risk areas, but not Worker input is documented in
and Remediation consistently throughout the faciltiy. Kaizen activities.
Process to correct hazards*** and unsafe behaviors No process to correct hazards and Little to no documentation of Process to correct hazards identified by Process to correct hazards Workers identify hazards and unsafe
identified by workers unsafe behaviors identified by hazards identified by workers. workers. identified by hazards and unsafe behaviors AND are involved in the
workers behaviors. corrective action / remediation.
Limited evidence of hazards Process includes prioritizing,
No process in place to receive corrected. remediation plan, completion dates and Consistent documentation, follow Positive EWB results validate worker safety
worker safety suggestions. measuring progress. up and completion. behavior shift.
Ad hoc worker safety suggestions
8
process. Significant gaps in documentation, A formal safety suggestion
follow up, and completion process and feed back loop to
workers who provided the input.
Process in place for worker safety Process is documented and
suggestions, but inconsistently used. consistently applied.
Industry trend analysis and benchmarking No benchmarking and evaluation Limited benchmarking and Process in place to evaluate external Process in place, benchmarking Process in place, benchmarking and
industry trends evaluation industry trends. May risks and industry trends -- inconsistent and industry trends identified. industry trends identified.
be adhoc and inconsistent. implementation.
6
Benchmarking places factory in Benchmarking places factory in the upper
the upper 75 percentile against 90 percentile against peers.
peers.
Industry trend analysis is reviewed as part
of the Hoshin process.
Culture of Safety: Levels of Maturity
Leadership
People
Process
RATINGS GUIDE
ADR
10 5 1
Approach:
•What structures and processes
have been developed to achieve One standard approach Beginnings of a standard No evidence that an approach has
the intent and why were they recognized as the Lean Best approach; missing some key been considered; reactive attitude to
chosen? Practice. elements of the Best Practice. needs or problems.
•How does this method align with
Lean Best Practice?
Deployment:
•There is no longer a separation between “Lean” and “Leadership.” Every leader utilizes Lean Thinking to run and improve their business.
Maturity Level 5 •Every leader has a master-level Lean coach. The primary role of Lean resources is coaching managers in the line of work.
10 The Legend •A well managed portfolio of projects covers every aspect of the business; kaizen activity is ongoing.
91-100%
R •A standardized, rapid improvement method is continuously practiced by managers who are coached by Lean Masters
•The status of virtually every process is immediately visible; the primary method for delivering results is the continuous monitoring and improvement of all processes.
A •Leaders understand Lean; view Lean as the means to improve processes and deliver results
T Maturity Level 4 •Full-time, dedicated Lean resources support all aspects of the organization
I 7 Record Holder
76-90%
•A well managed portfolio of projects is tied directly to strategy and focuses on process improvement
•A standardized, rapid improvement method is consistently led by Lean Coaches
N •Managers consistently deliver results by focusing on process performance and reacting to problems in immediately.
G •Leaders understand some basic Lean principles but treat Lean as a separate activity.
S Maturity Level 3 •Dedicated Lean resources are part time project managers
5 Olympian •A method to plan projects exists, but not clearly tied to strategy or process improvement.
51-75% •Organization beginning to define improvement methods, but skills and deployment depend on person
G •Results checked on a daily basis, but causes for those results are anecdotal.
U •Leaders understand Lean as “good” but don’t have personal responsibility
Maturity Level 2
I 3 Participant
•Projects launched in reaction to “pain points, roadblocks.”
D 21-50% •Methods not more detailed than “PDCA.”
•Management by reviewing retrospective, IT generated reports in weekly or monthly meetings.
E Maturity Level 1 •Leaders unaware of Lean
Spectator •Prevalent fire fighting
0 0-20%
•Success depends on heroics.
•Lack of structure & standards
Lean Maturity Model
75-90
Advanced
51-75 Leaders understand Lean;
Basics in Place view Lean as the means to
improve processes and deli
results
21-50 Leaders understand some Full-time, dedicated Lean
resources support all aspec
Beginning basic Lean principles but treat
Lean as a separate activity. of the organization
Dedicated Lean resources are A well managed portfolio o
part time project managers projects is tied directly to
Leaders understand Lean A method to plan projects strategy and focuses on
as “good” but don’t have exists, but not clearly tied to process improvement
personal responsibility strategy or process A standardized, rapid
Projects launched in improvement. improvement method is
reaction to “pain points, Organization beginning to consistently led by Lean
0-20 roadblocks.” define improvement methods, Coaches
Methods not more Managers consistently deliv
Ad hoc detailed than “PDCA.”
but skills and deployment
depend on person results by focusing on proc
Leaders unaware of Management by reviewing Results checked on a daily performance and reacting t
Lean retrospective, IT basis, but causes for those problems in immediately.
Prevalent fire fighting generated reports in results are anecdotal.
Success depends on weekly or monthly
heroics. meetings.
Lack of structure &
standards
91-100
High Performance
HS goals are fully understood by all levels and departments within the HS goals are mostly understood by all levels within the organization, and HS goals are in place, but they are not still being
organization across all departments trained across the larger organization
Management and worker’s HS goals are identical Management and worker’s HS goals are similar but not exact Management and worker’s HS goals are not consistent
Incentives only increase positive HS behaviors, dis-incentives are only Incentives usually increase positive HS behaviors, dis-incentives Incentives and dis-incentives are used that confuse
used to decrease negative HS behaviors generally are used to decrease negative HS behaviors positive HS behaviors
Respect between workers and management needs
Workers respect HS management, and HS management respect workers Workers respect HS management, and HS management respect workers
improvement
Collaboration between workers and management consistently and
Collaboration between workers and management generally occurs Collaboration may occur, but it is not consistent
constantly occurs
HS goals and objectives are clearly defined and fully understood by all HS goals and objectives are clearly defined and mostly understood by all There are HS goals and objectives, but they are not
levels within the organization levels within the organization understood throughout the organization
Management and worker’s goals and objectives are
Management and workers share identical goals and objectives Management and worker’s share similar goals and objectives
not consistent
HS goals and objectives are easily accessible by management and HS goals and objectives are not easily accessible to
HS goals and objectives are accessible to management and workers
workers management and workers
HS performance is measured and documented throughout all levels of the HS performance is measured and documented throughout most of the HS performance is measured and documented,
organization levels of the organization although not consistently throughout the organization
Management and workers contribute appropriately to the performance Management and workers contribute to the performance measurement Management and workers disproportionally contribute
measurement process process to the performance measurement process
Senior Management is aware of the HS programs but
Senior Management is actively participating in the HS programs Senior Management participates in the HS programs
has very limited participation
Senior Management leads the HS programs by giving input and Senior Management gives some input but does little to
Senior Management gives some input and recognition to HS successes
recognition of HS successes recognize the successes of the HS performance
Senior Management supports some of the efforts of
Senior Management champions the efforts and successes by the HS team Senior Management supports the efforts of the HS team—recognizing
the HS team but does not see it as a key indicator of
—recognizing that they are key indicator of organizational excellence that they are an indicator of organizational excellence
organizational excellence
HS is led by effective leaders throughout the organization HS leaders are mostly effective HS leaders are not always effective
Line Supervisors and Managers continually strive to increase their HS Line Supervisors and Managers are good, but do not always strive to Line Supervisors and Managers is not striving to
knowledge authority, and resources increase their HS knowledge, authority, and resources increase their HS knowledge, authority, and resources
Workers think/feel that supervisors and management are effective Workers generally think that HS is effective Workers sometimes think that HS is effective
The organizational structure has set management with a chart that The organizational structure has set management but the is incomplete The organizational structure does not correctly
highlights key HS personnel with regards to highlighting key HS personnel represent management or highlight key HS personnel
Management structure is good, but does not always promote appropriate Management structure is not striving to promote HS
Management structure promotes appropriate HS communication
HS communication communication
HS management beliefs are defined by management, but they do not HS management has communicated its beliefs but has
HS management beliefs are defined and put into practice by management
completely reflect what is put into practice not successfully put them into practice
Is there a set management structure and is there an organizational chart Interview management to discuss the organizational
HS personnel called out in the organizational chart.
highlighting key HS personnel? chart.
Review HS communication documents and discuss
Does the factory Management structure allow for appropriate HS
HS communication documented at all levels of the organization. with management how the overall management
communication?
structure promotes HS communication.
What specific ways does management translate their HS management Evidence of HS management championing HS beliefs--strong HS policies Discuss with management how they turn their beliefs
beliefs into practice? that are guided by HS management. into practice.
Activity Level Five Level Three Level One
The assessment proves the condition, behavior
The assessment proves the condition, behavior and/or actions and/or actions described in this category indicate
The assessment proves the condition, behavior and/or actions
described in this category indicate the following: the following:
INTEGRATED HS described in this category indicate the following:
• Virtually all activities and behaviors are fully and effectively • Basic compliance is achieved, and that all major
MANAGEMENT SYSTEM • General compliance is achieved, most activities and behaviors are
implemented, and risks are minimized as much as possible risks are reduced to an acceptable level
fully and effectively implemented, and risks are minimized
• Virtually all actions and behaviors are fully integrated into all factory • Actions and behaviors are managed separately
• Most actions and behaviors are mostly integrated into factory
operations from factory operations
Assessments, operations
• Management and performance exceeds local and international laws, • Local regulations, requirements and practices are
• Local and International regulations, requirements and best
Audits, Continuous regulations and best practices mostly followed
practices are mostly followed
• There is minimal room for improvement • There is significant room for improvement
Improvements • There is minor room for improvement
• The factory engages globally with stakeholders, NGOs. • The factory focuses on their issues
• The factory engages with key industry or local stakeholders
(IHSMS 2) Governments and other interested parties • There is an effective continuous improvement
• There is an effective continuous improvement program in place
• There is an effective continuous improvement program in place that program in place that is actively improving the
that is actively improving the system
is actively improving the system system
Internal and external assessments objectively evaluate compliance with Internal and external assessments objectively evaluate compliance with Internal and external assessments objectively evaluate
policies and procedures most policies and procedures compliance some policies and procedures
Internal and external audits are led by mostly effective leaders, but they Internal and external audits are completed by persons
Internal and external audits are led by effective leaders who strive to
don’t necessarily strive to increase compliance with policies and who don’t always strive to increase compliance with
increase compliance with policies and procedures
procedures policies and procedures
HS assessments are completed but not at all levels of
HS assessments are conducted at all levels of the organization HS assessments are conducted at most levels of the organization
the organization
All assessments are used to create action plans Corrective action plans are developed in most cases following audits Assessments do not always result in action plans
Workers are confident that corrective actions will reduce the risks in their Workers are not confident that corrective actions will
Workers are mostly confident that corrective actions will reduce risks
work reduce risks
Corrective actions are followed through but not always completed in a Corrective actions are not always followed through and
Corrective actions are followed through and completed in a timely manner
timely manner often not completed in a timely manner
Employees and management have complete confidence in the abilities of Employees and management are confident in the abilities of the Employees and management are not always confident
the assessment team assessment team in the abilities of the assessment team
Assessment team members are fairly effective—they
Assessment team members are effective—they are experienced with Assessment team members are mostly effective—they are experienced
are experience with much of the technical and
technical and management competencies that cover the full scope of the with technical and management competencies that cover much of the
management competencies but not always capable of
assessments scope of the assessments
covering the scope of the assessments
Does the risk recognition and reduction program include the development
of a hazard control inventory, establishment of a hazard analysis Completed hazard analysis procedures result in a hazard control Discuss with management how hazards are
procedure to identify existing and potential hazards, the implementation of inventory with documented procedures for risk control. inventoried and then controlled.
the procedure, and the design and implementation risk control measures?
Where applicable laws, regulations and standards are understood by all Laws, regulations and standards are mostly understood by all levels of Laws, regulations and standards are followed but not
levels of the organization the organization understood by all levels of the organization
Required laws are explained and posted Required laws are posted and often explained Most required laws are posted
Internal processes often exceed local laws and industry norms
There is an effective and timely update process There is a generally effective and timely update process The process is not very effective
The written procedure and documentation is
There is a written procedure and documentation that support the process The written procedure and documentation is not usually updated
incomplete
All persons on-site are given the same protections but not always held On-site personnel are not always given the same
All persons on-site are given the same protections and held accountable
accountable for violations protections of held accountable for violations
Non-employed personnel are given safety briefings and expected to take Non-employed personnel are given safety briefings but aren’t held Non-employed personnel are not always given safety
the same precautions as employees accountable for failing to take precautions briefings
Safe performance of work duties is fully understood by all levels of Safe performance of work duties is mostly understood by all levels of Safe work duty exists, but is not understood
employees within the organization employees within the organization throughout the organization
General safety standards, guidelines and rules exists,
General safety standards, guidelines and rules are fully understood by all General safety standards, guidelines and rules are mostly understood by
but is not understood by all levels within the
levels within the organization all levels within the organization
organization
There is an effective, timely, and interactive New Employee training There is a generally effective, timely, and interactive New Employee
The New Employee training program is ineffective
program training program
Employees work in a manner that is protected from the hazards Employees work in a manner that is protected from the hazards Employees do not always work in a manner that is
associated with their job associated with their job protected from the hazards associated with their job
There is an effective, timely, and interactive HS continuing education There is a generally effective, timely, and interactive HS continuing
The HS continuing education program is ineffective
program education program
Continuing education programs include all employees within the Continuing education programs include almost all employees within the Continuing education is inconsistently offered to
organization organization employees within the organization
Periodic evaluations are performed timely and effectively to ensure that Periodic evaluations are mostly performed timely and effectively to Periodic evaluations are not performed in a timely or
training and educational services are working ensure that training and educational services are working effective manner
Management progressively evaluates workers as it continually strives to Management evaluates workers, but is not necessarily striving to Management is not striving to increase HS
increase HS effectiveness increase HS effectiveness effectiveness
There is an effective, timely, interactive process for monitoring and There is a generally effective, timely, interactive process for monitoring
The process is not very effective
protecting employee health and safety and protecting employee health and safety
The negative HS factors have been identified but the mitigating work is The negative HS factors have not been identified
The negative HS factors have been identified and they have been
not always successful, or the HS factors that are identified are not correct and/or they have not been successful in mitigating
successful in mitigating those factors
but the work in mitigating those factors have been successful those factors
There is an effective, timely, interactive process for monitoring and There is a generally effective, timely, interactive process for monitoring
The process is not very effective
positively impacting HS activities outside of the factory and protecting impacting HS activities outside of the factory
The negative external HS factors have been identified but the mitigating The negative HS factors have not been identified
The negative external HS impacts have been identified and they have
work is not always successful, or the HS factors that are identified are not and/or they have not been successful in mitigating
been successful in mitigating those factors
correct but the work in mitigating those factors have been successful those factors
How to Assess Does the factory conduct periodic assessments to ensure that the leading Documented assessment process includes reviewing leading indicators Interview management about how they review leading
indicators are appropriate and are reducing risks and/or incidents? and how they are applied to reduce risks. indicators and look for appropriate documentation.
Interview management about how they use lagging
What lagging indicators does the factory track? Lagging Indicators: are after-the-fact measures for safety performance.
indicators and look for appropriate documentation.
Does the factory analyze and assess the lagging indicators to discover
trends, issues, or learn other information that can guide activities and Same as above, documented reviews track trends. Same as above.
programs to prevent similar incidents?
Activity Level Five Level Three Level One
The assessment proves the condition, behavior
The assessment proves the condition, behavior and/or actions and/or actions described in this category indicate
The assessment proves the condition, behavior and/or actions
described in this category indicate the following: the following:
HS PERFORMANCE described in this category indicate the following:
• Virtually all activities and behaviors are fully and effectively • Basic compliance is achieved, and that all major
MEASUREMENTS AND • General compliance is achieved, most activities and behaviors are
implemented, and risks are minimized as much as possible risks are reduced to an acceptable level
fully and effectively implemented, and risks are minimized
VALUE • Virtually all actions and behaviors are fully integrated into all factory • Actions and behaviors are managed separately
• Most actions and behaviors are mostly integrated into factory
operations from factory operations
operations
• Management and performance exceeds local and international laws, • Local regulations, requirements and practices are
• Local and International regulations, requirements and best
Using HS regulations and best practices
practices are mostly followed
mostly followed
• There is minimal room for improvement • There is significant room for improvement
Performance Data • The factory engages globally with stakeholders, NGOs.
• There is minor room for improvement
• The factory focuses on their issues
• The factory engages with key industry or local stakeholders
(PM 2) Governments and other interested parties
• There is an effective continuous improvement program in place
• There is an effective continuous improvement
• There is an effective continuous improvement program in place that program in place that is actively improving the
that is actively improving the system
is actively improving the system system
The results of the comparisons are documented and used to record The results of the comparisons are partially documented and often used
improvements and corrective actions to record improvements and corrective actions
How to Assess
Interview management about HS data storage and
Is the collected data housed in appropriate locations/databases? HS data is stored in a searchable database.
review the appropriate locations/database.
Are there reporting system mechanisms and recordkeeping systems in Same as above. Documented HS reporting mechanism outlines how Interview management to discuss HS data reporting
place to properly collect information in the performance measure scheme? records are collected and maintained. mechanism.
Is the data collected used to generate meaningful information and An analysis process is used to determine how collected data can result in Same as above. Review the role the data plays in the
continuous improvement? continuous improvement. continuous improvement process.
Interview management about the performance
Are the performance measures properly analyzed to ensure they are
How to Assess working as intended and appropriately?
Documented analysis of performance measures. measure analysis process and look for appropriate
documentation.
What methods, internal or external, are being used to analyze the
Performance data and program analysis documentation and process. Same as above.
performance data and programs?
Is performance data easily obtainable by personnel at all levels of the Discuss with workers and management how
Who has access to performance data and how they can access it.
organization? performance data is accessed.
Does the organization compare its results with like organizations to ensure
Performance data is shared with similar organizations via documented Interview management about how they share data with
that they are working in a proper manner, learning from these comparisons
reports and data tables. other organizations.
where appropriate?
How often does the organization compare its data and programs with like The data comparison process includes a schedule for how often the data
Same as above.
organizations? is shared and reviewed.
To whom does the organization compare its data and programs with? Data and program information sources are listed in the documentation. Same as above.
Activity Level Five Level Three Level One
The assessment proves the condition, behavior
The assessment proves the condition, behavior and/or actions and/or actions described in this category indicate
The assessment proves the condition, behavior and/or actions
described in this category indicate the following: the following:
described in this category indicate the following:
• Virtually all activities and behaviors are fully and effectively • Basic compliance is achieved, and that all major
HS PERFORMANCE • General compliance is achieved, most activities and behaviors are
implemented, and risks are minimized as much as possible risks are reduced to an acceptable level
MEASUREMENTS AND fully and effectively implemented, and risks are minimized
• Virtually all actions and behaviors are fully integrated into all factory • Actions and behaviors are managed separately
VALUE • Most actions and behaviors are mostly integrated into factory
operations from factory operations
operations
Effect on Triple • Management and performance exceeds local and international laws,
• Local and International regulations, requirements and best
• Local regulations, requirements and practices are
regulations and best practices mostly followed
Bottom Line • There is minimal room for improvement
practices are mostly followed
• There is significant room for improvement
• There is minor room for improvement
(PM 3) • The factory engages globally with stakeholders, NGOs.
• The factory engages with key industry or local stakeholders
• The factory focuses on their issues
Governments and other interested parties • There is an effective continuous improvement
• There is an effective continuous improvement program in place
• There is an effective continuous improvement program in place that program in place that is actively improving the
that is actively improving the system
is actively improving the system system
Management always tracks HS costs over time to determine increases Management partially tracks HS costs over time to determine increases Management infrequently tracks HS costs over time to
and decreases in expenses and decreases in expenses determine increases and decreases in expenses
Changes in expenses are always accompanied by analysis to determine Changes in expenses are frequently accompanied by analysis to Changes in expenses are inconsistently accompanied
what led to the change determine what sparked the change by analysis to determine the cause of the change
What process does the factory use to ensure its continuous improvement The continuous improvement process includes regular quality review of
Same as above.
efforts? the improvements.
Activity Level Five Level Three Level One
The assessment proves the condition, behavior
The assessment proves the condition, behavior and/or actions and/or actions described in this category indicate
The assessment proves the condition, behavior and/or actions
INTEGRATION OF HS AND described in this category indicate the following: the following:
described in this category indicate the following:
BUSINESS • Virtually all activities and behaviors are fully and effectively • Basic compliance is achieved, and that all major
• General compliance is achieved, most activities and behaviors are
PERFORMANCE implemented, and risks are minimized as much as possible risks are reduced to an acceptable level
fully and effectively implemented, and risks are minimized
• Virtually all actions and behaviors are fully integrated into all factory • Actions and behaviors are managed separately
• Most actions and behaviors are mostly integrated into factory
operations from factory operations
operations
Integration of HS • Management and performance exceeds local and international laws, • Local regulations, requirements and practices are
• Local and International regulations, requirements and best
regulations and best practices mostly followed
and Business practices are mostly followed
• There is minimal room for improvement • There is significant room for improvement
• There is minor room for improvement
Strategies • The factory engages globally with stakeholders, NGOs. • The factory focuses on their issues
• The factory engages with key industry or local stakeholders
Governments and other interested parties • There is an effective continuous improvement
(HSBP 1) • There is an effective continuous improvement program in place
• There is an effective continuous improvement program in place that program in place that is actively improving the
that is actively improving the system
is actively improving the system system
HS is a priority and therefore its alignment is considered when developing HS is a priority but is not always considered when developing the HS is not considered as a priority when developing the
the overall organization goals organization goals overall organization goals
HS & business compatibility is a priority but they are not in line with one Compatibility of HS & business performance is not a
HS & business compatibility is a high priority
another priority
HS performance is reviewed in order to evaluate its compatibility with the HS performance is reviewed for compatibility with the business HS performance is not reviewed for compatibility with
business performance performance but not regularly the business performance
HS performance is not always measured or used to
HS performance is measured and those results are used to evaluate the HS performance is measured but the results are not always used to
provide feedback on success/failure of implemented
success/failure of implemented programs evaluate the success/failure of implemented programs
programs
Successes and failures of implemented programs are
Successes are rewarded while failures are improved upon Successes and failures are not always recognized and responded to
not immediately recognized or responded to
HS performance is seen as a competitive advantage by the business and HS performance is not recognized as a competitive advantage by the HS performance is not recognized as a competitive
its customers customers advantage by the organization or its customers
Updates to the HS function mimic changes in other functions within the Updates to the HS function mimic most changes in other functions within Updates to the HS function mimic some changes in
organization the organization other functions within the organization
How to Assess How does HS performance contribute to competitive advantage and Methods management and sales use to demonstrate the value of their Interview management/sales representatives to
sustainability? HS performance. discuss HS performance as a competitive advantage.
Does the structure of the organization provide interactivity between HS Organization chart, schedules and minutes of meetings between different
Review appropriate docs and speak to management.
and other operational functions? operational functions.
Does the HS function address changes in other functions within the Review records of changes and compare the
Review change records.
organization? timeliness of organizational changes and HS changes.
Activity Level Five Level Three Level One
The assessment proves the condition, behavior
The assessment proves the condition, behavior and/or actions and/or actions described in this category indicate
The assessment proves the condition, behavior and/or actions
described in this category indicate the following: the following:
CONTINUOUS • Virtually all activities and behaviors are fully and effectively
described in this category indicate the following:
• Basic compliance is achieved, and that all major
• General compliance is achieved, most activities and behaviors are
IMPROVEMENT implemented, and risks are minimized as much as possible
fully and effectively implemented, and risks are minimized
risks are reduced to an acceptable level
• Virtually all actions and behaviors are fully integrated into all factory • Actions and behaviors are managed separately
• Most actions and behaviors are mostly integrated into factory
operations from factory operations
operations
Factors that • Management and performance exceeds local and international laws,
• Local and International regulations, requirements and best
• Local regulations, requirements and practices are
regulations and best practices mostly followed
impede or facilitate • There is minimal room for improvement
practices are mostly followed
• There is significant room for improvement
• There is minor room for improvement
success • The factory engages globally with stakeholders, NGOs.
• The factory engages with key industry or local stakeholders
• The factory focuses on their issues
Governments and other interested parties • There is an effective continuous improvement
(CI 1) • There is an effective continuous improvement program in place that
• There is an effective continuous improvement program in place
program in place that is actively improving the
that is actively improving the system
is actively improving the system system
Mistakes were clearly identified early in the process Mistakes are typically identified but not always quickly or early Mistakes are still not always identified
The management team involved in mistakes had a chance to learn from The management team involved in mistakes usually learn from those The management team involved in mistakes do not
these mistakes mistakes always learn from those mistakes
The workers involved in mistakes had a chance to learn from these The workers involved in mistakes now often have a chance to learn from The workers involved in mistakes do not always have
mistakes those mistakes a chance to learn from those mistakes
Ineffective projects are sometimes not analyzed to
Ineffective projects were analyzed to learn how to improve both that Ineffective projects are usually analyzed to learn how to improve both that
learn how to improve both that project and other
project and other projects project and other projects
projects
The projects considered mistakes are not quickly
The projects considered mistakes are quickly changed or modified to The projects considered mistakes are regularly changed or modified to
changed or modified to move towards success, or are
move towards success, or are dropped if success was not possible move towards success, or often dropped if success was not possible
not dropped if success was not possible
The positives from previous mistakes are clear The mistakes usually turn into positives The mistakes sometimes turn into positives
Mistake-driven celebrations do not occur with each
Mistake-driven celebrations occur with each occurrence Mistake-driven celebrations occur with most occurrences
occurrence
Management and Workers are equally celebrated Management and Workers are often equally celebrated Management and Workers are not equally celebrated
Mistake-driven celebrations occur frequently Mistake-driven celebrations occur infrequently Mistake-driven celebrations do not occur
The process is completely effective The process is mostly effective The process is generally not effective
Management and Workers are not always equally involved in this Management and Workers are not both involved in this
Management and Workers are equally involved in this process
process process
This process occurs frequently, and whenever needed This process occurs regularly, but not always as frequently as needed This process occurs infrequently relative to the need
Questions Things to look for How
Mistakes: Activities, actions, events, or other work that was conducted
that did not result in an outcome that was expected, or that did not result
in positive change; these occurred because of a lack of knowledge,
experience, or other accidental events rather than intentionally doing this Interview management and employees to discuss how
Are mistakes treated as learning opportunities?
wrong. mistakes are viewed and reviewed.
Learning Opportunity: A chance to provide teaching or other growth
chances Positives: Activities, actions, events, or other work that was
How to Assess effective in mitigating risks or good changes
Positives: Activities, actions, events, or other work that was effective in
Describe some mistakes and how they have been turned into positives. Ask management and workers to describe examples.
mitigating risks or good changes
Are mistake-driven improvements celebrated within the organization so
Evidence that workers and management feel as comfortable discussing Interview management and employees to discuss how
that other mistakes are not hidden, but are used as improvement
failures as they do discussing successes. mistakes are viewed and reviewed.
opportunities?
Documented review process that includes analysis to turn failures into
What is the process for taking negatives and turning them into positives? Same as above. Review appropriate documents.
successes.
HRMAT HRMAT User Guide
(RH1) Factory makes long-term investments to attract and recruit Factory has strategies, plans and channels to attract and Factory does not have focused strategies or plans to
high potential employees, such as partnership with recruit high potential employees. Sufficient amount of recruit high potential employees*.
universities and internship programs. candidates are available for screening and selection.
What recruiting efforts have you made to attract Effective recruiting activities. CHRO interview.
How to Assess operators? What is the result?
What strategies and channels do you use to Dedicated strategies, plans and channels. CHRO interview.
attract/recruit high potential employees? What is the
result?
High potential employee: Someone who has the ability, engagement and aspiration to rise to and succeed in a more senior and critical role. Examples are: university graduates,
engineers and managers.
September 1, 2011 53 of 73
HRMAT HRMAT User Guide
Hiring
HR partners with managers in interview and selection Functional managers take charge of interview and selection. HR function plays an administrative role in candidate
(RH2) processes. For some positions, the peers are also involved HR provides direct support in candidate screening and skills selection process, such as screening application forms
in interview process for candidates applying for the same testing. and conducting reference checks.
position or job function, so as to gain a more
comprehensive evaluation of the candidates.
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RECRUITING AND
HIRING
Job descriptions exist for all positions (operators, T/L&G/L, Job descriptions exist for all the key positions (e.g. T/L&G/L* Job descriptions exist for some but not all positions.
staff, management) with clear description of roles and and management), with clear description of roles and
Job Description responsibilities, required skills and competencies. Job
descriptions are regularly reviewed and updated.
responsibilities, required skills and competencies.
(RH3)
Job descriptions are used in employee development, such Job descriptions are used in recruiting process to convey clear Job descriptions are not fully developed, and do not
as performance evaluation and training needs expectations and requirements for target candidates. Job clearly describe the required skills and competencies.
identification. descriptions are specific enough to describe the requirements
of skills and competencies for the position.
How to Assess Is there clear understanding of the roles of job Level of understanding Workers and staff interview.
descriptions across the factory?
How are employees engaged in job description Level of employee engagement Workers and staff interview.
definition and review process?
How do you use job description in recruitment, The alignment between job descriptions, Review documents.
selection, performance evaluation and employee recruitment/selection criteria, and performance Interview related HR staff.
development? evaluation mechanics.
T/L&G/L (Team Leaders and Group Leaders): The shop-floor middle management who directly supervises operators.
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Extended orientation: Structured programs to equip new employees with job competency, including skill training, operation safety, 5S and quality requirement.
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Training Plan Training plans are based on need analysis. Needs analysis Training plans are based on need analysis. Procedure is in Factory conducts some training needs analysis. But it
(ED1) considers both internal and external factors, e.g., place to regularly assess training needs. Multiple factors are is reactive and inconsistent.
competency gap, business expansion, and new initiatives considered in the need analysis, including competency gaps
from customers. identified in performance evaluation results.
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EMPLOYEE Factory has a large variety of training programs to meet To best suit different training objectives, various training The training sessions are mainly instructor-led,
DEVELOPMENT different employee development needs. Examples are: methods are used, such as instructor-led training, coaching, classroom activities.
classroom courses, experiential learning, mentoring, night and experiential learning*.
school, outside seminars and continuous-education
programs.
Training
Programs (ED2) JI Training method is the major training method on the HR and other functions forms a dedicated team to drive JI Factory uses Job Instruction (JI) Training*, but there is
shop-floor. A large majority of T/L&G/L are competent JI training deployment. Factory has procedures to motivate, grow limited T/L&G/L involvement.
trainers and embrace JI training. and manage internal JI trainers.
* Experiential learning: The process of making meaning from direct experience. An example is going to the zoo and learning through observation and interaction with the zoo
environment, as opposed to reading about animals from a book. Thus, one makes discoveries and experiments with knowledge firsthand, instead of hearing or reading about others'
experiences.
*Job Instruction (JI) Training: Step by step on the job training method in which a trainer (1) prepares a trainee with an overview of the job, its purpose, and the results desired, (2)
demonstrates the task or the skill to the trainee, (3) allows the trainee to mimic the demonstration on his or her own, and (4) follows up to provide feedback and help.
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Does the factory engage with any external training? Process of engaging external training provider. Review documents.
What are the types of training needs that the factory External training provider evidence. Interview HR/Training manager.
cannot address within its internal expertise? How Training Needs Analysis documents.
does the factory approach external training
providers?
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How to Assess How is the evaluation result analyzed and Process to utilize training evaluation results Same as above
communicated?
How did you improve the training system based on Process to evaluate training system Same as above
the evaluation results in the last 12 month? Example of improvements on training system
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Evaluation Factory's performance evaluation systems are widely The goal, principle and procedure of performance evaluation Factory makes little effort to communicated the
System accepted and embraced by its employees. system are clearly defined and fully communicated to all
employees.
performance evaluation system to its employees.
(PM1)
HR function regularly leads self-assessment of the HR function plays a leading role in managing a factory-wide HR function is not managing a factory-wide
evaluation activities and systems, and drives continuous performance evaluation system. performance evaluation system.
improvement. Functional managers are equipped to conduct performance
evaluation effectively.
What efforts has HR made to equip functional managers Functional managers are equipped with capacities. Document review.
with capabilities in performance evaluation?
What are the key issues found in performance evaluation in Performance evaluation is continuously improved. CHRO interview. Document review.
the past 12 months? How are they addressed?
*KPI driven performance evaluation: A performance evaluation system that is mainly driven by quantifiable KPIs other than individualized goals.
*Performance review: Individual discussion between employee and supervisor regarding his or her past performance and future goals.
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Evaluation
Activities Evaluation results clearly state the future goals and gaps
for employees to overcome. They encourage, not
Evaluation results are carefully analyzed and fully
communicated to employees. Evaluation results serve as key
Factory has made little effort to analyze, communicate
or utilize the evaluation results.
(PM2) discourage, employees to grow towards desired
performance.
reference for other HR decisions, such as promotion, salary
appraisal, career development and trainings.
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Career
A large proportion of managers, T/L&G/L, engineers and A large portion of managers and T/L&G/L are promoted from Most managers and engineers are recruited externally.
Development staff are promoted from within. Many of them are promoted the worker level through career development programs.
(PM3) from the worker level. Factory has educational programs to support operator career
development, such as night school.
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HR partners with production planning, industrial HR partners with managers to identify gaps in operator skills, Current skill requirements are identified and
engineering, NOS and skills training departments to which is integrated and updated in production workforce documented, but they are rarely used in production
continually update workforce plans based on current and plans . workforce plans.
future skill requirements.
Are there written procedures to manage and review Documented procedures to check if factory periodically Review documents
working hours and production schedules? What action was reviews practices on the shop floor. Interview with HR staff
taken to prevent issues in the past 12 months? Documented conclusion after a periodical review.
How to Assess
What were the unusual business circumstances that A pre-determined strategy/backup plan to deal with unusual Interview with HR, production staff
interfered with the production schedule in the past 12 business circumstances Review practices under unusual business
months? How did the factory deal with them? circumstances
Does the factory update workforce plans based on current Updated workforce plans Look for documentation
and future skills requirement? Which departments are
involved?
*Workforce planning: The process for ensuring that a corporation has suitable employees to ensure future business success. "Suitable employees" refers to the right amount of
employees with the right skill and competency at operator, staff and management levels.
*Unusual business circumstance: Events which do not occur on a regular basis but interfere with production and cause delays, such as material delay, power shortage and quality
issues.
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WORKFORCE PLANNING All appropriate operators are trained and are capable of Multi-skill training and job rotation are routine for operators. There is some multi-skill training and job rotation for
performing multiple operations. HR has policies and procedures to support multi-skill training operators, but they are not routine practices.
HR policies create incentive to multi-skill training and job and job rotation. Multi-skill training is mostly conducted by production
Multi-Skill rotation.
HR drives the standardization of multi-skill training and job
Factory invests in sufficient resources to support multi-skill
training, including training facilities and qualified trainers.
departments with limited cross-department support.
How does the factory effectively utilizes current Best practices Interview HR, manager and multi-skilled workers
multi-skill workforce?
*Relief team: A team who replaces or relieves other workers when production has bottlenecks.
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*Succession planning: The process of ensuring a suitable supply of successors for current and future key jobs as defined by business strategy.
*Key job: The positions with great importance to factory management and development, including key management and technical positions.
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Are there procedures to engage employee representatives Example of policy changes in the past Interview CHRO, Trade Union/Worker Committee, and
How to Assess in policy changes? What are some examples of past policy Worker committee's participation in policy discussion 1-2 employees who were engaged in policy changes
changes and how were the employees engaged?
What methods are developed to evaluate communication Measurements and evaluation results Interview CHRO
activities and systems? What are the results? Review documents
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How and how often do operators interact with management Communication between operators and management, Interview with operators
(supervisor and senior management)? including line supervisors and senior manager Observe interaction between manager and workers
In the last 12 months, how did management and HR Examples of management and HR reaching out to listen to Review documents related to the activity
How to Assess proactively reach out and listen to employees' feedback? employee feedbacks
What training or programs are developed to improve Programs to develop communication skills of the managerial Review documentation of communication programs;
communication skills of managers and supervisors? How employees Interview at least one manager, one supervisors about
does the factory evaluate their effectiveness? the execution of programs
Are there employee representative groups in factory? Policy and procedures of employee representative Review documents
Why were they established and how are they groups Interview with chairman of key employee
developed? representative groups, such as trade union
Employee representative group (or working group): A group comprised of employee and/or management representatives, and has a clear purpose and structure. Examples are
ESH committee, Kaizen committee, worker committee and trade union.
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Does the factory have an HR strategic plan and Process and result of HR planning Review document. Interview CHRO
How to Assess performance goals? How are they established? What are
the results of execution?
How does the factory support the financial requirements of Process of gaining financial support for the HR initiatives Interview CHRO. Review document.
the HR strategic initiatives?
*Chief Human Resource Officer (CHRO): An senior officer who oversees all HR operations for the factory location. HR operations accounts for 50% or more of his or her
responsibility. Factory may use similar job titles such as HR Director, HR VP and Chief People Officer.
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HR staff competency is periodically assessed, gaps are HR staffing level and competencies are clearly defined. Actual HR staff has training opportunities, but the focus is on
identified and robust actions are taken to close the gaps. staffing and competency level match the plan. personnel transactions, not HRM processes.
STRATEGIC HR HR training program is routinely evaluated and updated. HR staff has sufficient development opportunities to improve
All functional managers are equipped with necessary HR their professional skills in both personnel and HRM processes.
expertise.
HR Organization Factory engages external consultants or organizations to
& Resources supplement internal HR expertise when necessary. In such
cases, factory seeks a sustainable solution.
(SHR2)
Factory uses its HRIS to support its HR strategic plan and Factory has the IT infrastructure (Human Resource Information HR has an IT system, but its function mainly supports
to continuously improve HRM processes. System or HRIS) to effectively support both personnel and personnel processes not HRM processes.
HRM processes.
Does the actual staffing and competency level of the HR HR job descriptions and competency evaluations Documentation review
organization match the plan? Interview CHRO
What trainings have the HR staff received in the last year? HR staff training plans and training assessment reports Documentation review
How to Assess How has it supported HR meeting its competency needs? Interview CHRO
What are the HR operations that can be supported by the Sufficiency of HR system infrastructure Interview related HR staff
IT system? Review HR IT system
What are the projects/functions in which the factory Case examples Interview CHRO and review case documentations
acquired external consultants? Why?
*Personnel processes: Transactional processes such as hiring and termination, payroll and compensation, records administration and adherence with labor law.
*HRM processes: Processes required to meet strategic business needs, such as recruiting and selection systems, training and employee development, communication and
employee engagement, workforce analysis and strategic planning, performance management, talent retention
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Analysis
Factory leadership incorporates HR data analysis in the Factory leaders are informed on a timely basis about the HR Factory is aware of its HR issues, but has not taken
(SHR3) strategic planning process and key business decisions, issues. Factory has consistently taken effective strategies and effective measures to address them.
such as HR policy formation, expansion, and actions to address the issues, such as recruiting, training,
reorganization. succession planning and restructuring.
How do you capture the intangible HR factors, such as Tools to measure the intangible factors. Document review
employee satisfaction? How do you ensure the reliability of Objective, statistically valid employee satisfaction survey Interview related HR staff
the data and its analysis?
How to Assess What are the top 2 HR issues in the last 12 months? How Data analysis to identify issue and root causes. Interview senior leadership.
do you identify the root causes? How has the factory Effective countermeasures deployed Documentation review
addressed these issues? What are the results?
How is the workforce data analysis used in strategic Examples of senior leadership incorporating the analysis in Interview senior leadership.
plans and business decisions? strategic planning and decision making. Documentation review
*Workforce data: Qualitative or quantitative attributes that indicates the status of factory workforce (employees at all levels), such as quantity, age, years of service, turnover,
absenteeism, productivity, grievances, reasons of resignation and satisfaction rate.
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*Corporate values: Beliefs about what kinds of goals members of a corporation should pursue and ideas about the appropriate standards of behavior members should use to
achieve these goals.
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Continuous
Improvement Factory's HRM practices are frequently benchmarked by Factory's HRM practices are benchmarked by other Factory's HRM practices are not benchmarked by other
other manufacturers, including those from other industries. manufacturers in the sporting goods industry. Factory openly manufacturers.
(SHR5) Factory has taken an industrial leader position in HRM by shares its HRM practices in conferences, workshops and
sharing in conferences, industry journals, or through other benchmarking activities in the sporting goods industry.
benchmarking activities.
How does the factory conduct self-assessment? Standards, process and result of self-audit CHRO interview and documentation review
How to Assess What are the critical HR issues identified in the past 12 Specific cases of continuous improvement CHRO interview and case review
months? How are they identified and addressed?
Please give examples of the factory taking an industrial Specific cases that demonstrate leadership CHRO interview and case review
leader position.
*HR metrics: Metrics that measures the effectiveness of factory HR practices. Examples include: number of work injury, average OT hours, percent of recruitment plan achieved,
employee satisfaction with training, turnover in key jobs, managers' satisfaction rate with HR services and HR cost per sales dollar.
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