I was recently doing some development training for a global manufacturing company with a large presence here in North America. Overall, this organization has a great safety culture and has a pretty comprehensive safety management system. Not surprisingly, their TRIR (Total Recordable Incidence Rate) is currently below 1.0. However, they are actively looking for steps to get to 0.5 or lower and take the next step in terms of their safety journey.
In preparation for my training, I was reviewing some of their incident reports from the past year and noticed a similar trend. Regardless of the department where it occurred, the nature of the event, or the employee’s experience level, none of the injuries were due to any safety rule violations. In addition, they all tended to occur on tasks that were rare or unexpected. In some of the incidents, investigations revealed that there were actually no documented procedures for how to safely complete one of the steps in the process because it was rare or had such little risk associated with it. Simply put, these were not simple, garden variety safety incidents. They were more complex, and had various potential precursors related to anything from ergonomics to training to equipment maintenance.