The document describes how a company used Six Sigma to reduce motor vehicle accidents (MVAs) among its employees. It outlines the Define, Measure, Analyze, Improve, and Control (DMAIC) methodology. The company analyzed 25 work-related MVAs over one year to identify key risk factors. These included not focusing on driving, lack of situational awareness, not checking behind vehicles when backing up, and not wearing seatbelts. The company developed new driver training programs, checklists, and ongoing data collection and review processes to address these risks. As a result, MVAs decreased by 68% over the target 50% reduction in the following year.

1. BREAKTHROUGH IMPROVEMENT IN H&S PERFORMANCE THROUGH 6 SIGMA Presented by ALI irfanSix sigma master bloack belt (iqf) coo & chief trainer ideas

2. PRESENTATION INCLUDES What is Six Sigma? Why Six Sigma? Why Six Sigma used for HSE improvement? Case Study?

4. Data driven decisions

5. Breakthrough performance gains

8. Dependent

9. Output

10. Effect

11. Symptom

12. Monitor

13. Response

14. X1 . . . XN

15. Independent

16. Input-Process

17. Cause

18. Problem

19. Control

20. FactorY = f(X1 + X2 + ... Xn). Why should we test or inspect Y, if we know this relationship?

22. Unsafe drinking water almost 15 minutes each day

23. 5,000 incorrect surgical operations per week

24. 50 Newborn Babies Dropped At Birth By Doctors Each Day

26. Breakthrough performance gains Sigma is a statistical unit of measure which reflects process capability. The sigma scale of measure is perfectly correlated to such characteristics as defects-per-unit, parts-per million defective, and the probability of a failure/error.

27. Traditional TQM approach Process Output (Y) Inputs (x)

28. Six Sigma Approach....... Key Process Input Variables Process Inputs Output KPIVs Variation Inducing Parameters VIPs Critical Variation Inducing Parameter CVIP

29. What are HSE Defects? - Fatalities - Reputation of injuries - Injuries (LTI) - Days / Time away from work (LTA)

31. Reduce Defects (DPMO)

32. Center Around Target (Mean)

36. Difficult to Measure- Lost Opportunities - The Hidden Factory Average COPS approximately 15% or even higher of Sales

38. Measure

39. Analyze

40. Improve

44. Phase 01 - Define To address the MVA problem, Company created an MVA project team. After creating a project charter, which defined the project’s timelines and objectives as below. Reducing MVAs by 50 percent over a 12-month period

45. MEASURE Phase 02

46. the team began to collect information on the variables associated with MVAs. These included factors related to ; the accident (output), the driver (Input) and the vehicle driven (Input) , along with details of the accident itself. Phase 02 - Measure

47. ANALYZE Phase 03

48. After identifying the variables associated with MVAs, the team divided them into three categories of possible risk factors (Input): Methods, People, and Environment. Phase 03 - Analyze

49. Phase 03 - Analyze

50. Possible MVA Risk Factors (KPIVs)

51. Analyze- (contd.) Variables in the methods category were related to driving skills; Risk factors in the people category were largely behavioral; and Variables in the environment category were related to both the driver and the condition of the environment.

52. Analyze- (contd.) The team next performed a root-cause evaluationthat analyzed the probability of each risk factor occurring and determining whether it was measurable. The team studied the police and accident reports of the MVAs and surveyed the drivers involved to determine which factors played key roles in the accidents.

53. Analyze- (contd.) The analysis confirmed that the following four variables (VIPs) contributed to (i.e., were the root causes of) most of the Company’s MVAs: Not focusing on driving tasks in general; Not having a clear picture of surroundings (e.g., not properly evaluating road conditions, other drivers); and Not checking behind the vehicle before backing. Not wearing Seat Belt while driving.

54. Analyze- (contd.) Through its analysis, the team determined that all of the accidents involving backing up and due to seat belt were avoidable as were 81 percent of the other accidents. It means that these two factors are C-VIPs

55. IMPROVE Phase 04

56. Phase 4- Improve the team developed a series of driver procedures or steps to address the risk factors. For Example All drivers involved in MVAs are now required to complete a course on defensive driving and have their driving observed by a supervisor in an "in-car" driver improvement course.

57. Improve- (contd.) These drivers develop a "Learning Experience Report," which is shared with other employees. In addition, topics pertaining to driving are discussed at monthly environmental, health and safety meetings.

58. Improve- (contd.) Every employee must also review a 10-step "Arrive Alive" checklist before driving a company-owned or -leased vehicle, and suggested procedures for backing up and guidelines for using cell phones are provided.

59. 10 Steps to Arrive Alive I realize that my number 1 priority right now is to drive this vehicle safely and without incident to my destination. I have checked behind the vehicle for obstacles; it is safe to back this vehicle if needed. I am mentally and physically alert and am capable of making this trip. I have securely fastened my seat belt and adjusted it for proper fit.

60. 10 Steps to Arrive Alive I am aware of the weather and realize that it can change during my trip. I will adjust my driving technique to allow for darkness, fog, rain, ice, etc. I will be alert for traffic and road hazards and adjust my driving to safely allow for them. I will obey all posted highway traffic signs. I have a good attitude toward my driving, and I will be courteous and allow for other drivers’ mistakes.

61. 10 Steps to Arrive Alive I am devoting my undivided attention to safely operating this vehicle, and I will not allow distractions to take my mind away from driving. I know the five keys to safe driving Aim high in steering Get the big picture, Make sure they see you, Keep your eyes moving, and Leave yourself an out, and I will practice them as I drive to my destination.

62. CONTROL Phase 05

63. Phase 5 - Control The project team developed and held a series of specific presentations, some with general information geared to all drivers, and others with more in-depth information for drivers involved in MVAs and/or who drive over 30,000 miles per year in an assigned vehicle.

64. Phase 5 - Control The project team also established new criteria for investigating future MVAs that provide for the continuing collection of relevant data. All MVAs are now the subject of root-cause investigations, and the findings are reviewed and tracked by an MVA reduction team. As new risk behaviors are identified, this team is responsible for developing appropriate corrective measures and employee education programs.

65. Result …….. The company experienced only 8 MVAs during 2008-2009. Reduction in MVAs is 68%, which is more than the targeted 50%.

66. Questions ? ?