Roadmap for Deploying an Enterprise Operating System in HSE

From Lean Production to a Safety Culture

Integrating HSE issues into the overall enterprise production system is a natural stage of development for large industrial holdings. Isolated initiatives by specialized professionals often face environmental resistance, whereas embedding safety into basic operational processes changes the production culture itself. In his presentation, Alexey Kuzin, Head of the Ecology and Technosphere Safety Department at the Bryansk Machine-Building Plant (Transmashholding), examines the practical experience of deploying an enterprise operating system where safety acts as a connecting link for all production cycles.

A Five-Level Roadmap as an Integration Tool

The foundation for implementing changes was a roadmap built on the principle of maturity levels. The speaker shows that it is impossible to create ideal conditions instantly — the system requires sequential progression through five stages, from basic data registration to creating a fully accessible environment.

• Coverage of all processes: Safety requirements are embedded in every section of the operating system, including management, the 5S system, transport management, and equipment maintenance (TPM). This prevents HSE from developing in isolation from production realities.
• Internal and external benchmarking: Constant comparison of performance indicators between areas and plants of the holding stimulates continuous improvement and the exchange of effective practices.
• Phased defense of levels: Transitioning to the next stage is only possible after the actual completion and defense of the previous level's measures, which eliminates a formalistic approach.

Practice of Working with Microdata: From Medical Center Visits to Ergonomics

The presentation details the mechanism of working with primary employee requests for medical assistance. At the first level, the system only requires the registration of all visits to the medical center (including complaints about blood pressure or back pain). At the second stage, the data array is analyzed, which allows identifying systemic problems — for example, a high percentage of visits related to osteochondrosis.

This leads to the transition to the third level: the development of specific solutions. Separating ergonomics into a distinct process resulted in a reduction of labor severity through the purchase of new equipment and the testing of exoskeletons. At the fourth level, the actual reduction in the number of visits is evaluated, and at the fifth, workplaces with a high level of ergonomics are created, including for people with disabilities.

Transformation of Risk Assessment and Visual Management

The speaker emphasizes that static risk assessment documentation does not work in a dynamic production environment. To maintain the relevance of safety matrices, a system of regular checks has been implemented.

• Abandoning the "green zone": Changing the color of acceptable risk from green to turquoise helped break the employees' stereotype that low risk does not require attention. This visual solution forced personnel to realize the need to manage even minimal threats.
• Multi-level audit: Checking the relevance of risks has been transferred to the shop floor level. First, it is conducted by the foreman, then by the worker under the foreman's guidance, and at higher maturity levels, cross-self-audits between areas are introduced.
• Safety workstations: Visual management is implemented through shop floor boards, which host not abstract posters, but real tools: a safety cross, workplace risk assessment standards, and foreman checklists.

What you will learn from this webinar:

• How to build a 5-level HSE development system and integrate it into production processes?
• How to use medical center visit statistics for targeted improvement of workplace ergonomics?
• Why changing the color in the risk matrix can affect workers' attitudes towards safety?
• How to involve line managers and the workers themselves in the process of regular risk assessment updates?
• What visual management tools actually work on the production floor?