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TRANSCRIPT
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FRITO LAY & STOP Training
DuPont™ STOP™
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FRITO LAY & STOP Training
• ABOUT PEPSICO
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FRITO LAY & STOP Training
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FRITO LAY & STOP Training
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In the Beginning…
• History of Safety School – Started in 2004
• Each site had its own • Aberdeen’s (STARS – Safety Training At Risks Systems)
– In 06/07 combined 3 FL sites programs • (Aberdeen, York, Williamsport)
– Designed for Repeat Offenders
– Scheduled after work hours
– Course was made up of 6 classes • Ranging 1 ½ to 2 hours in length
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Pitfalls
• DISADVANTAGES
• VERY TIME CONSUMING
• Attendance tracking nightmare
• Make-up scheduling problems
• Took forever to get Employees completed
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DuPont STOP Seminar
• 2008, started hearing good things about – DuPont STOP training systems
• Leadership and Safety bought into the idea
• Ordered books and started classes – Repeat offenders – Management Team
• GREAT RESULTS – Implemented across site for all Employees
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What we did…
• Establish Ground Rules
• Set Agenda/Schedule
• Who will Participate in Class
• Make it a Comfortable Atmosphere
• Customized to meet our needs
• Outcome / Results
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Ground Rules
• Ground Rules (may add additional for each class)
– Start / Stop on Time – Be Respectful
– No use of Electronic Equipment – No Side-Bar
– Frequent Breaks/Stretching – Vegas Rule
– Dead Horse Rule
Daylene’s saying of the day:
• DON’T DWELL ON THE PAST, LEARN FROM IT
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What works for us…
• AGENDA • TWO – EIGHT HOUR DAYS
– Day One • Start 7:00 AM w/ Introductions and LED IN • Unit I – 2 ½ hours • Unit II – 1 ½ hours • Unit III – 2 ½ hours
– Wrap up and Discussion for Day One
– Day Two • Recap of Day One • Unit III completion – 2 ¼ hours • Unit IV – 2 hours • Unit V – 2 Hours
– Wrap up with LT and review of issues list
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No Debate…
• PARTICIPATION – MANDATORY
– Cross Function of Employees
– No more than 2 from the same Classification
– Mix of At-Risk and Safety Minded Employees
– All New Managers are Required during onboarding
– Schedule classes every other Period • (if time and dollars permit)
– Invite Internal and External visitors
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Welcoming Setting…
• Comfortable Settings • Food
• Furnish Breakfast (Bagels, Donuts, Fruit) • Lunch/Drinks • Candy/Prizes
• Frequent Breaks – Keep class going 75 minutes, MAX
• Change up of Teams – Pull numbers to pick teams
• No 2 persons from same dept. or shift – Re-org teams on Day Two
• Visit Areas that you normally don’t work in • Partners from another plant location
• ALLOW TIME FOR PLENTY OF DISCUSSION
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Make it Fit your Site…
• Customization – Talk Job and Plant Specific Incidents
– Add personal touches/stories
– Show injuries and accidents from local papers
– Share stories of tragedy from fellow co-workers
– Utilize “YouTube” for Safety Shorts
Incidents/Injuries
• PREVENTABLE or
• NON-PREVENTABLE
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PERCENT PREVENTABLE? a)50% b)90% c)95% d)99%
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PERCENT PREVENTABLE? a)50% b)90% c)95% d)99%
(majority of the time, 100% by classroom vote)
OUTCOME & RESULTS
• Since starting STOP Training
– Over 250 Employees and Managers Graduated
– Less than an 8% Return Rate for 2nd Round • Employees can complete 2 rounds of STOP Classroom
– 2 Day – 8 Hour Course
• 3rd Round is conducted by LT & Safety Manager – (condensed version)
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COST
• The Average Class cost: – Wages
• 14 x $20.00 x 16 hours = $4,480.00
– Food • Breakfast, Snacks, Lunch = $500.00
– Materials • Initial Material Cost from DuPont • Materials as needed
COST OF THE AVERAGE CLASS AROUND $4,980.00 plus Materials
Hidden cost (OT on the floor)
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What Questions might you have
about Safety School?
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