Pilot IMS Birmingham - Case Studies - Manufacturing: Extrusion

Extrusion

One feature of the extrusion process is the relatively high cost of process start up and shut-off. This feature demands the integration of all associated processes and the use of a three shift system for maximum operational efficiency. The problems of access to the workforce for training purposes flow directly from these requirements. To minimise the effect of these problems, our Trainer/assessors are based at the workplace, so that they are always on hand and immediately accessible for any learner and we split their working days in order to cover all three shifts.

Companies in this sector we have worked with include:

Adaptaflex Ltd. / Cable Management Systems Ltd.

Baggeridge Brick plc

Durapipe UK Ltd.

Example of Programme undertaken

Programme Details
Our initial project was to introduce a change of culture towards health and safety within the whole 500+ workforce at the five production facilities located across Britain. This was in support of an industry-wide pledge initiated in 2004 to dramatically reduce the number of workplace accidents being experienced in the UK industry.

Preparation
Our plan was to deliver the certificated City & Guilds Health and Safety in the Workplace course to all members of staff, accommodating both the shift patterns and the working practices for a continuous, automated production facility. Management and Supervisors were to be the first to undertake the course to give them a full understanding of what would be required of their staff and to gain their support for the ongoing programme.

Course Delivery
Delivery of the course sessions was achieved through a series of 2 hour or 4 hour workshops at each factory location.

To drive home their responsibility for safety, the management groups were given additional theory and project work. They were tasked with identifying current hazards in their workplaces and to produce fully prepared proposal to neutralise at least one of their identified hazards. The Company's Directors accepted every one of the resulting recommendations and implemented them without delay.

The course was then rolled out across the Company. It was followed up with a comprehensive DVD covering the Company's products, production processes and health and safety requirements. This DVD was issued to every member of the Company, acting as a training aid and permanent reminder of their individual responsibilities while at work.

Outcomes
Outcomes experienced are:

a heightened awareness amongst all staff of their responsibilities towards health and safety, with some staff scoring full marks in the final knowledge test
the immediate introduction of new safety measures
compliance with statutory requirements relating to health and safety in the workplace
additional/ongoing training courses for volunteers across the organisation
a standard package of Company and health and safety information issued to all staff as a reminder of the learning covered and as an induction tool for all new employees taken on by the company at any of its sites
a marked reduction in accidents reported and time lost through injury.

Those who have already completed their course and gained their qualification have all reported their delight and enthusiasm for the work. This shows both in their increased confidence and in their performance at work. The course demonstrated to the Directors and to many of the individual participants that they had capabilities that had previously been unexposed and underused. This was evidenced by their empowerment to take on fresh responsibilities, including staff representation on the Works' Health and Safety Committees.

With the satisfactory results of this comprehensive health and safety initiative, the Company embarked on a programme of developing the staff within various production and office departments. The ongoing programme of courses being followed includes:

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