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The Smurfit Kappa Group is a world leader in the paper-based packaging industry producing over 12 million tons of paper annually and operating over 300 plants and mills worldwide. Headquartered in Dublin, Ireland, The Smurfit Kappa Group employs more than 40,000 employees with operations in Europe, Latin America, Canada, Singapore, USA and South Africa. Products manufactured include containerboard, corrugated containers, boxboard, solidboard, graphicboard, and other paper-based packaging products.

Challenge

  • Ensure manufactures and suppliers worldwide are using the most up-to-date documents associated with product design specs and manufacturing processes.
  • Implement a system facilitating the upload and storage of documents easily accessible to global manufacturing and supplier facilities.

Intelex Solution

  • Intelex Safety Incident Reporting Application

Results

 

  • 58% reduction in lost-time accidents
  • 63% reduction in number of absent days through injury
  • Accident frequency rate reduced from 1.9 to 0.83 per annum
  • Accident severity rate reduced from 32.52 to 8.55 per annum
  • Improved status within Smurfit Kappa Group resulted in winning 2009 European
    Safety Award

Objective

With dozens of manufacturing sites across the UK, each using their own variation of a paper-based safety incident tracking system, The Smurfit Kappa Group wanted to remedy this disjointed approach and implement a web-based, user-friendly software system to track and manage their safety incidents consistently across their UK manufacturing sites.

The system needed to be accessible to all employees at each site and allow them to easily record incidents, hazards and near misses. With management requiring monthly reports from each site containing metrics such as Days Since Lost Time Injury and Accident Frequency and Severity Rates, the system also needed to be able to perform these calculations and generate real-time reports and dashboards.

Implementation

Operating on Intelex’s Web-Based Platform, the Safety Incidents Reporting Application provided a centralized reporting system, accessible via the web by any employee at any location. Employee IDs were imported into the system and Smurfit Kappa’s paper incident form was translated into an easy to complete digital version. A simple user interface was configured so that upon logging in, users are presented with the incident form, ready to be completed and submitted.

An initial Intelex training session for Safety and Environmental Managers from each geographic location was conducted, after which they were able to train the users at their respected locations. As users confidence has grown more modules are set to be launched to improve other aspects of the company and further drive forward continual improvement.

Extra

Return on Investment

Saved Time & Resources
Eliminated time and resources spent completing and processing paper forms. Data
is entered directly into the system and is instantly available via real-time reports and
dashboards.

Standardized Process and Centralized Data
Established a consistent incident tracking process across all locations and centralized all safety performance data in one location easy to retrieve and analyze.

Improved Accuracy & Quantity of Data
User-friendliness of application resulted employees recording all occurrences of incidents, near misses and hazards improving the ability to trend and analyze data. Near miss reporting improved by 64%.

Improved Business Performance & Reduced Costs
Decreased lost time accidents improving business performance and reducing associated costs while gaining competitive insurance premiums.

  • Mark Montgomery, Compliance Manager

    " Intelex’s Safety Incident Reporting Application provided such a high level of visibility into our safety performance that we were able to identify areas for improvement that would have never been uncovered otherwise. Detecting root causes and driving corrective and preventive actions, it has been a critical component to the success of our entire safety program and maintaining OHSAS 18001 conformance. "