GH Hensley Industries' safety goal is simple: zero injuries. After five years of using a behavior-based process, Hensley's three-person safety staff cut back lost-workday injuries-while the employee population grew 34 percent and production increased over 47 percent-from 28 in 1990 to seven in 1991, and four in 1992. Since August 12, 1992, there hasn't been a lost-workday accident.
Back in 1991, this Dallas, Texas, steel foundry was a 385-employee facility experiencing 3,641 lost workdays. Incurred costs for workers' comp reached $1.5 million a year. So the company hired Safety and Environmental Manager Jerry Berryhill. Along with Carol Dunmyer, R.N., and Larry Parra, safety specialist, the team has instituted a behavior-based process, including worker committees and awareness campaigns. Engineering controls and visible management commitment are also integral to the process' success.