Culture-Driven Safety Transformation

Background:

Multiple manufacturing sites faced safety risks, poor morale, and high turnover.

Challenge:

• Turnover >70%, leading to inconsistent training and high onboarding costs

• TIR above 4.5 created a culture lacking leadership accountability

• Reactive management undermined employee trust

Actions Taken:

• Implemented Leader Standard Work and daily Gemba Walks

• Embedded 5S discipline and PDCA problem solving

• Built a family-centered safety culture with transparent leadership

Results:

• Turnover cut from 72% to 17%

• TIR reduced from 4.5% to 0.89%

• Workforce engagement significantly improved, establishing a lasting safety culture