Case Studies
Goltra Castings Company
Interview with Larry Draper, General Manager
SITUATION: Goltra Castings Company is a steel foundry that specializes in carbon, low alloy and corrosion-resistant high alloy castings for a variety of customers that include railroad, construction, farming and the oil industry. The foundry environment includes six induction furnaces, molding, coring, heat treating and finishing equipment. The work performed at the foundry is difficult and can be dangerous. Although efforts have been made in the past to improve safety, no dramatic improvements had been realized.
“I could no longer ignore the data presented to me again and again by Hellman & Associates. They made an effective business case to support changes in our work practices.”
PROBLEM: Goltra Castings’ injury rate was well above industry average and its workers’ compensation premiums were excessive. The company was a risk to insure and the situation was not improving. The company did not know where to begin and they needed help.
“Hellman & Associates evaluated our safety program and held it up to industry Best Practices. They convinced us that safer and more effective practices were available.”
SOLUTION: In 2007, Goltra contracted with Hellman & Associates to improve their safety record and manage their safety and health program. A baseline Prioritization of Issues Assessment was performed to evaluate program and physical facility deficiencies. Historic injury reports were reviewed, new procedures and safety rules were developed, and routine training of management and employees was initiated. In just a few months, Goltra went from having essentially no safety program to one where hazards were being identified and actively eliminated.
“Hellman & Associates helped us identify what was truly important and they guided my supervisors into a strong safety leadership role.”
RESULT: With Hellman & Associates’ assistance, Goltra was able to reduce their injury rate by nearly 70 percent once a comprehensive safety program was put in place during the first year. Following the initial year, safety program installment and active management, Colorado Cost Containment Program certification was achieved and frequent and costly injury events no longer occur.
“We had been curious about Colorado Cost Containment but had no idea how to begin. Hellman & Associates took care of us ‘from A to Z’ and continue to do so.”
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L'Oreal USA
Interview with Grant Pearson, Director of Operations
SITUATION: L’Oreal USA’s Aurora, Colorado Logistics Center is an expansive and efficient distribution facility with 120 employees working together to distribute products world-wide. This particular L’Oreal facility had an excellent safety program and injury and illness statistics, but the management had a greater vision for the program. Achieving VPP status seemed like the best way to realize that vision and they strove to be the first distribution center within L’Oreal to be accepted into the VPP program.
“My goal was to take the existing corporate framework for the safety management program and move it further so that we always went above and beyond what was required of us in terms of safety and health compliance and employee protection.”
PROBLEM: L’Oreal USA’s Director of Operations knew he wanted to apply for VPP status, but was unsure if he was ready and worst of all, where to begin. After determining that they could not be mentored by a sister distribution operation located on the East coast, they decided to get help locally. Having worked with Hellman & Associates in the past for other projects, he knew it was the perfect fit to provide the guidance and support needed.
“We understood that we were committed to achieving VPP status as a top priority. The problem was we felt we did not have the expertise in house to help us make that commitment a reality. We wanted trusted professionals to be our partners through the entire process from evaluating our administrative requirements to walking the facility with the VPP audit team.”
SOLUTION: L’Oreal USA partnered with Hellman & Associates to assist them with managing requirements of the VPP application processes. The Hellman & Associates team utilized the OSHA VPP Site Worksheet to evaluate any gaps with the key VPP elements and worked with L’Oreal management to complete the VPP application. In addition, the consultants participated in the onsite evaluation to answer questions and provide information to ensure the audit team’s proper understanding of equipment and processes.
“By having the support of a team of experts, it took us less time and fewer resources to address the administrative and onsite tasks so that the management’s focus could remain on the employees and the continued implementation of a stellar safety and health program.”
RESULT: With Hellman & Associates’ assistance, L’Oreal achieved VPP Merit status and join the elite group of employers who have received this recognition. The partnership continues to benefit the organization by keeping management focused on long-term safety goals and the need for continual improvement of the program.
“It was surprising how this experience significantly broadened my awareness of what safety encompasses. Our employees better recognize the spirit and value of the program. Though the process felt laborious at times, it was comforting to know that we had partnered with a consulting firm that could provide us with the support we needed to improve our program. With Hellman’s assistance in providing much needed expertise and knowledge, we achieved our initial goal of VPP Merit Status and are working toward our next goal of Star Status.”
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Cummins Rocky Mountain, LLC
Interview with Bill Alexander, Vice President of Service
SITUATION: Cummins is the world’s largest designer and manufacturer of diesel engines ranging from 55 to 3,500 horsepower. Cummins Rocky Mountain is the second largest distributor in North America, providing 24/7 sales and service in nine states. They employ more than 500 people at 14 branch locations. With this vast geography comes the challenge of standardizing all aspects of the business, including safety programs. By instituting consistent practices, the company saves money.
“An effective safety program is a commercial activity – an investment to achieve a good return.”
PROBLEM: Cummins Rocky Mountain was experiencing inconsistent safety practices between locations, and some branches weren’t even addressing basic measures. In the past, the company had developed in-house safety programs, as well as, hired several different consultants, but were regularly dissatisfied with the results. Ineffective recommendations coupled with an ever-changing safety initiative caused management to lose confidence in the benefits of the program.
“The single biggest problem was inconsistency from location to location. Additionally, some of the consultants we worked with in the past would make suggestions that were within regulation, but implementing them would have actually made our situation more dangerous. Our safety program lacked credibility and therefore management was just going through the motions. They didn’t think this was an effective way to spend money.”
SOLUTION: Cummins Rocky Mountain contracted with Hellman & Associates to develop an environmental health and safety program with checks and balances to ensure consistency throughout the organization.
“Now we do the same thing at every location. Every branch has the same type of safety manual, compliance calendar and training. The program is presented in an organized, standard way, so we spend less time than we did two years ago, yet incidences have decreased and safety knowledge has increased. It’s becoming a repetitive activity. There is a checklist so we consistently address basic issues. It gives us a level of control so our people don’t get hurt.”
RESULT: Over a 12-month period, Hellman & Associates has helped Cummins Rocky Mountain to decrease OSHA-reportable incidents by 26%. Not only are branch locations safer, but the increase in productivity also translates to their bottom line. Management is now committed to the program because they’ve seen a decrease in lost workdays and savings of both time and money.
“Hellman & Associates has become our partner, and they give us a high level of response and attention. They’ve demonstrated that when we have them look at a problem or do an audit, they come back with good recommendations that decrease our risk. The quality of their work has gotten credibility because they evaluate the intent of each regulation and what makes sense. It’s evident they’re aware that we have to continue running the business. There is no doubt in my mind that we’re getting back every dollar we invest, and our improvement has justified our ongoing relationship.”
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Coblaco, Inc.
Interview with Steve Davis, President
SITUATION: COBLACO Services, Inc. provides industrial cleaning, painting and architectural blasting services. Much of their work is performed at their 30-acre site and within their 15,000 square foot paint shop. As the company grew, it became cumbersome for management to understand and keep up with government regulations and maintain a consistent safety program. They’d looked into outsourcing, but there were few programs that addressed their needs.
“A lot of other safety consulting companies work in emergency-type situations. Hellman & Associates is the only company we found that would help us stay in front of things so that they’re addressed before we have a problem – prior to when the authorities come on site.”
PROBLEM: COBLACO’s mod rate had been steadily increasing – a considerable expense to the company. They were challenged by lack of time and inefficient processes in handling their environmental health and safety (EH&S) issues. Additionally, safety credentials were often required when they went to bid on large projects. As a small business, however, they lacked the budget for a full-time safety manager.
“We didn’t have time for the implementation of safety measures and lacked qualified personnel to do that. We were doing the things we needed to do to satisfy requirements, but it was reactionary and inconsistent.”
SOLUTION: COBLACO contracted with Hellman & Associates to manage their EH&S program and identify areas where they needed improvement. This allowed management to spend less time addressing safety issues and more time building the business and providing quality service to customers.
“With Hellman & Associates, we know our safety program is consistent, up-to-date and there aren’t any unknowns. It’s freed up my managers so they’re more productive because they don’t have tofocus on safety concerns, and that impacts our bottom line. Now, everything runs smoothly and the greatest thing is that I don’t have to worry about it. I’m sure that I’m compliant.”
RESULT: With Hellman & Associates’ assistance, COBLACO was able to lower their mod rate from 1.03 to .83, and the company has been able to maintain cost containment certification. The partnership has reduced accidents in the workplace and introduced a safer work environment.
“Through Hellman’s expertise and knowledge, COBLACO has reduced injuries, significantly lowered worker’s comp costs and implemented new safety practices in a cost-effective manner. They’ve guaranteed our compliance and nearly eliminated the possibility of future citations. They also successfully led us through two investigations where their knowledge of the regulations proved to be invaluable. We’re a safer company for having them around, and that’s good for our employees and good for our company. And there’s an additional benefit we’ve experienced: One of the best things that they’ve brought to us is a sense of credibility with some of the larger contractors we’ve worked with. Now we can say we have someone on our staff that can address and take care of safety issues.”
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