Safety School – Key Elements in Reducing Injury Rates

From Semi-Knocked Down Assembly to Systemic Safety

The development of automotive manufacturing inevitably entails the complication of technological processes and an increase in headcount. The transition from semi-knocked down (SKD) to completely knocked down (CKD) assembly at the Moskvich plant (formerly Renault) revealed a critical problem: standard introductory and initial briefings were insufficient to ensure workplace safety. The speaker discusses how the rise in injury rates and the concealment of accidents became a catalyst for an in-depth analysis of incidents and the revision of the entire HSE system at the enterprise.

Analyzing Causes of Injuries and Revising Standards

An in-depth analysis of injuries showed that most incidents were related to a lack of understanding of the importance of using personal protective equipment (PPE) and violations of basic safety rules. The presentation details the process of revising documentation: from procedures to specific HSE instructions. An important step was realizing that employee fatigue, hidden illnesses, and ignoring equipment malfunctions (for example, temporarily fixing parts with masking tape) directly affect the level of safety.

Creating the "Safety School" and 10 Golden Rules

To solve the identified problems, an internal "Safety School" was created in 2008. The training is based on 10 key rules covering the most critical aspects of production: electrical safety, working with robotic cells (LOTO system), interaction between forklift drivers and pedestrians, operating lifting equipment, working with chemicals, PPE usage, ergonomics, and the emergency response system. The speaker demonstrates by example how practical stands help employees understand risks: from forklift blind spots to the importance of using specialized gauntlets during welding.

Practice-Oriented Training and Employee Engagement

Training at the "Safety School" lasts about two hours and includes a theoretical part, practical exercises on nine training stands, and final testing. Importantly, the school is constantly evolving: originally created from scrap materials in the workshop, it is now located in a comfortable office space and is accessible to all employees, including office staff. The safety culture is supported through regular audits (Safety Gemba), the "Stop-Risk" program, which allows assembly line workers to independently identify and eliminate hazards, and a system for prompt incident reporting.

What you will learn from this webinar:

• How to transition from formal briefings to practical safety training?
• Which 10 safety rules are the most effective for a manufacturing enterprise?
• How to organize an internal "Safety School" with minimal costs?
• How to use training stands to demonstrate real production risks?
• How to engage assembly line employees in the process of identifying and eliminating hazards?