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Apex Engineering International, L.L.C.: Not a Single Work Day Lost in 4 Years |
Apex Engineering International, L.L.C. |
Apex Engineering International, L.L.C. (AEI) of Wichita,
Kansas has manufactured aircraft components for commercial, regional and
military markets of the aerospace industry for more than 50 years. Plant I
produces detail aviation parts, while the assembly is accomplished at Plant II.
Several years ago, AEI acquired the assets of a failing company leading to many
significant changes. It was learned that there had been three major accidents
over the past three years that resulted in the loss of fingers and hands with
the use of the newly acquired machinery. In the words of new President and Chief
Executive Officer Jeff Landreth, "Something was very wrong and had to change
immediately." He also said, "I believed a world class company should care as
much about its employees as it does about its profits."
Events soon began that would lead to a cultural transformation for AEI. A
Director of Safety was hired. A Safety Board was formed with representatives
from every employee group of the company and given the task of establishing
safety policy. And then, AEI began to take a hard look at their safety record.
Many interesting and revealing facts and trends were discovered during the
safety evaluation that proved to be extremely beneficial for AEI. It was learned
that 42 percent of all accidents involved new employees within their first year
of employment. Wednesdays were the worst day of the week for injuries. The worst
month of the year for injuries was July. A major injury such as the loss of an
eye, hand or finger was occurring every 18 months. Most injuries involved
material handling. Workers compensation costs were soaring. It was also revealed
that the company lacked both a training plan and a daily equipment safety check
list/procedure. This detailed review provided AEI with information they used to
identify and focus on safety problem areas.
With the help of the free, confidential Occupational Safety and Health
Administration (OSHA) on-site consultation services provided by the Kansas
Department of Labor, AEI began to tackle their safety problems. Larry Landreth,
Director of Safety, wrote "Under the leadership of the OSHA consultation
program, we began to see immediate results and a new perception was established
for our company."
Many changes were instituted. A safety orientation program was developed and a
safety handbook was created. A buddy program was implemented to pair every new
employee with a seasoned employee for 20 days; the seasoned employee ensures the
new employee learns and performs all job tasks safely.
After making many safety improvements, the Safety Board voted to compete for the
Safety and Health Achievement Recognition Program (SHARP) Award. In February
2008, AEI received the highest safety designation bestowed on small businesses
by OSHA for exceptional commitment and dedication to effective safety and
occupational health management systems. During the SHARP Award presentation,
Judy Freeman, Area Director, OSHA-Wichita Area Office said, "Getting to be a
SHARP site is no small undertaking. SHARP criteria are stringent. Apex
Engineering International, L.L.C. has undergone a rigorous review process by the
State of Kansas consultants."
There have been many other rewards for AEI. In 2006, when the Total Recordable
Case (TRC) industry average rate was 6.3, AEI’s rate was 4.7. As of January
2009, there has not been a single work day lost during the past 4 years despite
a significant increase in the number of employees. Jeff Landreth reported, "Our
workman’s compensation insurance rates have dropped dramatically saving the
company money, the employees can come to work in the morning knowing that they
will make it home to their families at night without getting hurt. Productivity
is higher because we have no lost work days due to injuries. Most of all though,
I sleep better at night knowing that I didn’t contribute to the injury of one of
our most valuable assets—our employees."
In any manufacturing business, there are many dangerous machines and a lot of
opportunities for injuries. The employees of AEI have noticed the difference the
commitment to safety has made for their company. One employee referred to the
safe working environment at AEI as "the backbone of success." Another said, "It
is nice to go to work at a place that has my best interest at heart." A third
employee said, "I find myself teaching my family safety practices that I have
learned at work."
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