A higher level of safety culture.

A fifth level of safety consciousness. – Creating a safe and productive work environment.

Robert Pater describes four levels of safety culture. These are forced, protective, involved and leadership.

Many of the places I visited during my work as a sales rep for a boiler repair company fell into the first group. Actually maybe there needs to be a lower group as sometimes I saw places where worker safety was completely ignored. In others, the safety policies were forced upon the workers and managers alike. Every one there felt safety was a burden and OSHA was out to shut them down. There was some truth in that, but not for the reasons they felt.

The workers themselves even rebelled against the safety protections because they were forced by the safety police to comply. They felt the PPE and other protections were just another form of repression.

I have also seen many plants that work on the second level. These are the plants that Pater says have a lot of procedures that don’t get followed when no one is looking. I used to work on a plant where one guy actually said in response to a reprimand, “I did not know that was a procedure we were actually supposed to follow.” And he was serious.

In the protective mode, the managers feel they have to impose safety for the employee’s own good. They feel they have to protect them from themselves in spite of themselves. The safety director here is often detached from the work environment and lots of money and effort goes into promoting the flavor of the week safety campaigns. I suspect a lot of the people who come to my web site looking for free safety slogans work in these types of environments.

Next up the scale are the involved plants. These are places that have made a lot of progress in safety and here I usually see a lot of safety teams doing safety stuff. There is probably a safety suggestion program. As Pater points out, these facilities often hit a plateau where improvement is stifled by their previous progress. The last facility I worked at had reached this point. I got really annoyed when one of my workers got injured trying to implement one of the safety suggestions made by the safety committee.

Pater’s summit level is the leadership level. At this level, safety is done by people, for themselves. There is a true belief that all accidents are preventable. Management actively champions safety. The culture is proactive and morale is enthusiastic. There is a real emphasis on engagement and getting everyone as involved as possible.

Plants like this are unfortunately rare. Few ever make it past the involved level as the safety team structure is self limiting. When the safety consciousness evolves to the leadership level, the safety directors and safety teams are no longer needed. The safety ego steps in to protect itself and limits the transition to the higher level.

I would actually love to see a plant that operated at an even higher level of safety consciousness. This would be a creative level. At this level, there would be no conscious thought directed at preventing safety problems because there would not be any to prevent. All procedures would be written to reflect the safest and most efficient way to produce a quality product with minimal adverse effect on the environment. There would be no energy given to preventing accidents. Instead the total focus would be on the desired outcome. In this environment, employees would focus their entire attention on doing theirs jobs well. There would be no thought of injury or pain.

In some ways this level sounds like the sub level one plants; but in practice, it is the complete opposite. In the sub level one safety consciousness, there is not thought given to the well being of the people. In the creative level, the well being of the people involved is the primary concern. At this level, the well being of the people and the facility are the same. People are focused on creating quality product as safely and efficiently as possible.

The most important step in achieving a level five facility is believing that it is possible. The results of the facility will be a vibrational match to the people involved in the process. People that focus on accidents and accident prevention will continue to see accidents. People who believe in a creative safety culture will see an environment where there is no need for safety policies and procedures. The standard operating procedures will instruct employees in the safest, most efficient way to create quality products.

Again, the safety ego of the facility is often the greatest hindrance to achieving this step. Once a facility approaches the creative level of safety consciousness there is no longer a need for safety directors and safety teams. These people have worked themselves out of a job.

However, if their energy and efforts are shifted instead to creating a safe and productive work environment, all will benefit even more. In the lower four levels, the safest way for employees to act is not to work. However this method is not really in the best interest of their overall well being. At the creative level of safety consciousness, employees’ well being is best served by working according to the established work practices and producing quality goods for which they are well paid.

If you would like to learn more about how to transform your safety consciousness to that of creating a safe and productive work environment see http://strawsolutions.com

Repairing my ball joint press

I bent my Harbor freight ball joint press while pressing in the bottom joint. I did not notice that it got a little crooked and I kept pressing. I should have pressed it back out and started over, but I kept going. I hoped just a little more pressure would straighten it out. It did, but my press frame bent in the process.

Despite assurances by my millwright friend that it could never be brought back to parallel, I was able to straighten the c clamp in my Dad’s press.

Using a press to fix a press
Using a press to fix a press

I pressed each end slightly and measured the distance between the two sides of the press. I had to over compress a bit as it would spring back slightly when released. I suspect it has lost some strength in all the bending but I think it will still be strong enough to do the other two ball joints if I am careful. If not, Harbor Freight has them on sale now.

Septic System Sump Pump Installation

Septic System Sump Pump Installation

My friends needed a septic system that pumps uphill. Their house is at the low point on their plot and for years the septic system has not worked well. They needed to fix it so that they can have toilets that actually flush in the rain. An unusually wet Spring season has accented the problem so that they made the decision to spend the sizable sum of money to correct the problem.

The system consists of the regular septic tank then a septic effluent pump tank and then a distribution tank located at the top of the hill. The new septic tank had to be placed so as not to disturb the old tank so that the existing system could still be used during construction. The pump tank had to be located slightly below the septic tank so that gravity would flow the waste water to it. The septic tank effluent pump sits inside the pump tank and pumps the water to the distribution tank high on the hill. From there, the water will drain into the field lines by gravity.

My job was to connect the sump pump and alarm to the electrical supply. The alarm is required by the local sewer codes to make a visual and audible alarm should the water level in the pump tank exceed a certain level. This gives an early warning that there is something wrong with the sewer pump.

For reliability, the alarm has to have its own separate circuit. If the alarm was powered by the supply to the pump and the breaker tripped to the pump, there would be no alarm. I installed the alarm inside the house so that it can be easily seen and heard as suggested by the local plumbing inspector. I connected the wires directly to the alarm panel and ran them all inside conduit so that it would be tamper resistant.

This house had an exterior breaker box originally installed for the AC addition. This box had a couple of extra spaces in it that made a perfect place to pull power for the new septic pump system. I used a 20 AMP GFI breaker for the sump pump service and a 15 AMP standard breaker for the alarm. Their local ACE hardware had the right breakers for this older Square D box.

The most labor intensive part of the job was running the underground wires from the box at the front of the house to the septic field behind the house. Much of the trench had to be dug by hand due to close proximity of the AC compressor, flower beds and a sidewalk. The majority of the trench was dug by the plumping contractor using his backhoe.

A 12 gage wire was run for the pump and a 14 gage wire for the alarm. The wire used was rated for direct burial so conduit was not needed. I did run conduit for extra protection from the box down to the bottom of the 24 inch deep trench at each end of the wire. I used the same 14 gage direct burial wire to extend the float wiring from the alarm unit to the field.

At the pump tank, I installed a weather proof single 20 AMP outlet on a 4×4 post. This is where the Myers Sewer pump is plugged in. The plug provides the required local disconnect since the breaker is not within sight of the pump tank. The float wiring was placed in a separate junction box on the same post.

A piece of conduit was cut to fit into the neck of the tank so that the cord to the septic pump and the alarm float wiring would be protected. The conduit ends slightly below the outlet for the septic pump.

Our local inspector was happy with the details and water proofing. I used a compression fitting at the bottom of each conduit run and sealed it with silicone as well to prevent critters from finding their way into the junction boxes.

I tied a length of rope to the sump pump, fastened the alarm float to the outlet pipe and carefully lowered the sewer pump into place. I secured the free end of the rope to one of the lifting lugs of the sewer pump tank. Now the plumbing contractor can finish his work to get their system operational.

I am sure they will enjoy being able to take baths and flush the toilet even when it rains.

How to Prevent Workplace Violence

Violence in the workplace has long been an issue for managers to deal with. Unlike other workplace safety issues, the dramatic nature of the events makes them difficult to prepare for.

The causes of workplace violence are many and varied. However, the chances of having a workplace violence incident in your facility will be greater when there is a hostile atmosphere. High stress workplace environments also lead to work place violence issues.

Often domestic disputes and other outside influences such as drug deals and other outside interests play out in the workplace. While these outside factors may be out of our direct control, there are ways of reducing their impact on the operation.

One precursor of workplace violence that needs to be carefully controlled is horseplay. While workers need to have freedom to express themselves, horseplay can quickly get out of hand and have dangerous if not fatal consequences. I suspect injuries due to horseplay are severely underreported due to the nature of the interpersonal relationships.

In order to reduce the chances of a workplace violence incident, you need to create a safe and empowering work environment. Employees who feel good about themselves will not feel the need to increase their self worth by bringing down others. Workplace bullying and workplace violence go hand in hand.

Promoting good team work where each person’s value in inherent in the system will help everyone feel better about themselves. A quality employee performance system will also help aid employees self esteem. The better and more valuable employees feel about hem selves the less likely they will be to attack others in a effort to improve their status. Also, people who feel good about them selves will not attract violence into their lives.

A belief in some form of lack is usually the basis for workplace violence. When people feel that there is not enough money or not enough time or more often not enough recognition to go around, they begin to attract violence to themselves so that they can become a victim. Or they may lash out at others in defense of some supposed injustice.

Many workers feel that intimidation is the only way they can feel good about themselves. They like to harass other workers, especially new hires. If these people are rewarded for teaching and training new or slower workers, they will get the self esteem boost they need with out resorting to the hazing that leads to violence.

As managers, we can find ways to boost the self esteem of our workers. I once had an electrician who, while very intelligent, had difficulty getting along with his fellow workers. He would get belligerent when people questioned his intelligence and the other workers become fond of finding ways to make him look bad. I put him in charge of developing our lock out tag out plan. He felt self worth because he had been asked to perform sun an important task. Other people were forced to work with him because the procedures he developed they would have to follow for posterity. They also began to respect him because they saw the amount of time and research he had to put into each procedure. After only a few days into the project the hazing and arguing peacefully disappeared.

Another worker I had liked to harass new workers. He had been with the plant from the day it opened and loved to show off his expertise. He refused to follow new safety rules and generally made life miserable for a lot of people. My boss wanted to find a way to early retire him and the union even tried to get him fired.

I put him in charge of training new workers. He got the recognition he deserved. He began to feel good about himself and his contribution become valued to both the company and his fellow workers. He could be the hero trouble shooter without having to cause problems in the first place. Through this simple job restructuring, both the company and the employee benefited. So did all his co workers.

When dealing with specific problem employees, you need to get to know them and make an effort to understand their values. The need to feel valuable and important is universal. Finding ways to help people feel good about themselves will not only help reduce violence in the workplace, but will benefit productivity as well.

By creating a safe and validating work environment, employees will feel good about themselves. Make sure they know what is expected of them and be consistent in the response when employees fail to meet expectations. Expect only the best from your employees and do what you can to remove the blocks to their best performance.

Good, solid policies and procedures are critical to maintaining a safe work environment. When everyone knows what is expected of them and knows how to do their jobs, every one will feel better about themselves. They will inherently know when they are doing a good job without the need for constant supervision. People who feel good about themselves will not act violently toward others nor will they attract violence onto themselves.

While the causes of workplace violence are varied and complex; preventing workplace violence is as simple as addressing these key areas. Make sure employees are rewarded for working well together. Make sure employees feel they are making a valuable contribution and make that value known to others. Make sure people know what is expected from them in the workplace and be consistent in the implementation of the policies and procedures.

To learn more see Straw Solutions Safety Coaching program.

From Street Car to Rally Racer to Rock Crawler.

From Street Car to Rally Racer to Rock Crawler.

The metamorphosis of a Jeep Cherokee

Scuffy II started out as an ordinary little Jeep Cherokee. When I was ready to build my rally racer, I wanted a two door Cherokee with a five speed transmission, six cylinder engine and 4 wheel drive.

An Ebay search turned up almost what I wanted. There were only two problems. The Jeep was an 88 with the Renix engine controller and it was in Pennsylvania.

However, the price was right so I made a deal, hooked up the trailer and headed north. My dad and my son went along for support.

We arrived early in the morning to pick up the Jeep. We were expecting to have some fun loading it because the owner said the clutch would not disengage. This was one reason it was being sold cheap. I noticed that even though it was very cold out side, the little Jeep started up very easily.

I had my dad drive the trailer down the street a bit and drop the ramps. I put the Jeep in low range and hit the key. Sure enough it lurched forward and started up just fine. I had just enough room to line it up with the ramps and drive smoothly onto the trailer. I cut the key and the Jeep stopped at just the right spot on the trailer.

The owner who had gone inside to get the title came running out asking how I had fixed it so quickly. My dad just smiled and said; “He is good with Jeeps.”

This is how it looked when we first got it home:Rally Jeep Beginning XJ Cherokee

To sort it out I did a few rally crosses with it:Jeep Cherokee XJ Rallycross

I even raced it in one autocross. It really looked funny on autocross tires. It drove even worse.Jeep Cherokee Autocross racing

Soon I was ready to make the commitment to building a true rally racer. I decided on the SCCA PGT class. This class was for four wheel drive vehicles over 2.5 liters and less than 5.0 liters displacement. Minimum weight was 3000 lbs. It seemed a good fit for the Cherokee

The trouble was everything about the engine and body had to be completely OEM stock. This was tough and expensive on an old Jeep. There were many simple mods that I could have made that would have been cheaper than the stock parts, however, they were not allowed. Turbo cars were allowed external engine computers that upped their power output greatly. This put the Jeep at a horsepower disadvantage to the Subarus.

More Ebay searching turned up approved racing seats and harnesses. I traded for a roll cage and borrowed a computer and driver’s suit.

RallyJeep was born. A quick coat of racing white paint and a set of SCCA decals and we were ready for our fist race.

Rally Jeep Cherokee 100aw

Between rally races, I began enjoying the sport of off road driving. I built a cheap jeep to see how much I would enjoy the sport.
Jeep Cherokee off road XJ

Just as I was beginning to see that off road driving was huge fun and I was meeting lots of interesting people off road, the sport of rally racing took an unexpected turn. SCCA dropped their rally series and my favorite race – Cherokee Trails – was canceled forever.

An assessment of my situation showed me I had a very nice and expensive Jeep that was pretty much useless to me. I had a cobbled together collection of parts that was lots of fun to drive and a great support group that was fun to meet with.

I decided to make the commitment and convert my RallyJeep into Scuffy II the off road Jeep. This would put my lockers and 4.7 L Stroker engine to good use. And I would not have to deal with a weak carbureted engine and slipping transmission on my off road trips.

First I mounted the ARB equipped D30 front axle in place. Knowing I would add lift later, I modified the area above the control arm mounts for extra droop.
Modified dana 30 axle

Next I installed the ARB compressor.
ARB Compressor Jeep Cherokee

I also installed a lock rite equipped 8.25 in the rear that had been living under my Daily driver Jeep. I did make a couple more rallycrosses before adding the lift. The lockers really helped in the mud on rainy days.

I finally made the ultimate commitment and pulled the lift kit off Scuffy and put it on Scuffy II. My first off road trip was to Beasly knob running the 30“ tires form my daily driver. The lockers made a big difference but the small tires were just too limiting in the rocks.

Next came fender trimming and the 35” tires. The front was easy. I just traded fenders between the race Jeep and Scuffy’s already trimmed fenders.Lifted Jeep Cherokee fenders trimmed

At this point I could still go back to rally racing with about four hours work.

However, the rear tires simply would not work without more clearance than the stock wheel well provided. It took a bit of soul searching, but I finally made the commitment to irreversibly modify the rear wheel arches. Actually, I can probably still cover the mods with the stock flares and race it again if I ever choose to.

Here is how it looked with the winch mounted:
Jeep cherokee XJ off road

My first real off road adventure with the new set up was to Harlan, Ky. I was really happy with the extra control that the manual transmission gave me. Especially when going downhill. I also got to test the new winch pretty well as we used it to pull a Dodge Ram pickup up a very step muddy hill.

The most recent modification to Scuffy II has been to make the doors removable. Having the doors off greatly improves visibility and add to the open air feeling. The two door doors are also very heavy so there is a noticeable performance improvement with the doors off.
Jeep Cherokee removable doors

This Jeep gets way more use now than it ever would have as a rally racer. Driving off road has taught me many lessons about life and helped me build many great relationships.

Also, I find the thrill of conquering obstacles off road gives me every bit as big of an adrenalin rush as racing through the woods at speed. I feel really safe with the rally spec roll cage protecting me off road. Knowing the cage was designed for a seventy mile per hour impact give me a lot of confidence at fifteen MPH trial speeds.
Jeep Cherokee off road XJ 33

Overall, this Jeep has given me a lot of fun and adventure. I expect to have many more fun adventures as I learn to drive the Jeep and keep reinforcing the weak spots.