An integrated framework for improving safety, quality, and stewardship standards in manufacturing: A case study

Abstract

Health and safety, quality assurance, and stewardship control, when integrated together, can streamline systems and work processes, reduce bureaucracy and increase efficiency. In this study, efficiency increase refers to improving and maintaining high standards of demarcation, housekeeping, no blocked safety equipment, tools storage conditions, good manufacturing practices and chemical storage conditions. Using industrial engineering tools, Plan-Do-Check-Act and Kaizen, the study illustrates a quick turnaround in standards improvement in a manufacturing plant, which resulted in culture change and increasing profitability. The manufacturing plant studied had below average standards that created health and safety hazards leading to incidents, created a risk of quality and stewardship systems failure. Incidents varied from minor to serious. With improved standards, the plant avoided and eliminated health amd safety, quality, and stewardship risks in critical areas such as production or operations floor, warehouse, laboratory, storeroom, utilities area, and workshop. This was achieved through the integration of health and safety, quality assurance and stewardship controls as one safety, quality, and stewardship (SQS) framework. The three are denoted as fundamentals and core foundation systems in a manufacturing environment in this study. An SQS tool was developed, tested, and implemented and results are shared. Implementation of the tool resulted in improvement of overall manufacturing plant standards, elimination of safety hazards, reduction of quality defects and scrap, eradication of internal controls issues, and business success. The study will be of great value for manufacturing plants who are looking to integrate more than two management systems.