Transforming EHS Performance and Driving Global Standardisation in Automotive Manufacturing

Advanced Automotive Component Manufacturing (Tier 1 Supplier)

Employees

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Facilities

0

Continents

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Pre-Implementation Challenges:

Highly Fragmented Data Management

Managing EHS data across disparate geographies, legacy systems, spreadsheets, and paper processes.

Reactive Incident Management

A reactive approach to incident management hindered root cause analysis and the implementation of effective corrective actions.

Manual Audit
Challenges

Manual audit and inspection processes were labour-intensive and error-prone, leading to audit fatigue and potential compliance gaps.

Compliance Challenges Across Locations

Inconsistent EHS practices and reporting across geographically dispersed facilities posed significant compliance risks.

Limited Performance Visibility

Lack of clear visibility into leading and lagging EHS performance indicators hindered proactive risk management and improvement efforts.

Safety Culture and Engagement Gaps

Difficulty in cultivating a proactive safety culture and achieving meaningful employee engagement in EHS initiatives.

Navigating Evolving Global Regulations

Staying current with rapidly changing global environmental regulations presented a significant and ongoing challenge.

High Insurance
Premiums

Elevated insurance premiums due to a high incident rate impacted the company's bottom line.

Solution Selection:

Following a rigorous evaluation process, the Client selected Emex due to our comprehensive, cloud-based, mobile friendly EHS Management System, and chose to prioritise the following:

Key Processes:

Incident Management & Investigation

Audit &
Inspection Management

Risk Assessment
&
Management

Compliance Management

Training Management

Shared Features:

Analytics
& Reporting

Corrective
Actions

Document Management

People
& Companies

Premium Options:

Premium Administration

API Toolset

Implementation Overview:

To ensure a smooth and successful implementation, a multi-phased approach was adopted, prioritising high-risk facilities and processes. This phased rollout allowed for a controlled and iterative implementation, minimizing disruption and maximising the chances of success.

A dedicated cross-functional team, comprising EHS professionals, IT specialists, and plant managers, was assembled to oversee the implementation. This team provided the necessary expertise and coordination to ensure a seamless transition.

Recognising the importance of user adoption, extensive training and change management programs were conducted. These initiatives aimed to equip employees with the necessary knowledge and skills to effectively utilise the new system, while addressing any concerns or resistance to change.

To ensure a smooth integration with existing systems, careful planning was undertaken for data migration and system integration with ERP and HR systems. This step was crucial to avoid data inconsistencies and ensure a seamless flow of information across the organisation.

Finally, the system was configured to support both global standardisation of EHS processes and compliance with local regulatory requirements. This flexibility allowed the organisation to maintain a consistent approach while adapting to the specific needs of different locations.

Results & Benefits

Significant Reduction in Incident Rates:

  • 35% reduction in total recordable incident rate (TRIR) within two years.
  • 40% decrease in lost-time injuries, resulting in substantial cost savings.
  • Enhanced root cause analysis and corrective action implementation, preventing recurrence.

  • Improved Compliance and Reduced Regulatory Fines:

  • Automated regulatory updates and compliance tracking reduced non-compliance incidents by 60%.
  • Streamlined audit and inspection processes reduced audit preparation time by 55%.
  • Reduction of regulatory fines by 80% over 3 years.

  • Enhanced Safety Culture and Employee Engagement:

  • Mobile EHS application empowered employees to report hazards and incidents in real-time.
  • Increased employee participation in safety training programs, with a 25% improvement in completion rates.
  • Improved communication and collaboration on EHS issues through centralised platform.

  • Increased Operational Efficiency:

  • Automated workflows reduced administrative overhead for EHS tasks by 65%.
  • Real-time dashboards and analytics provided actionable insights for proactive risk management.
  • Reduction of insurance premiums by 20% due to improved safety record.

  • Data-Driven Decision-Making and Continuous Improvement:

  • Advanced analytics enabled the identification of leading indicators and proactive mitigation of potential hazards.
  • Customisable dashboards provided real-time visibility into EHS performance across all facilities.
  • Standardised global EHS program, allowed for easy benchmarking, and improvement.

  • Improved Risk Management:

  • Proactive risk assessments allowed for the identification, and mitigation of potential risks, before they resulted in incidents.

  • Key Takeaways

    A comprehensive EHS management system can drive significant improvements in safety performance, compliance, and operational efficiency. 

    Global standardisation of EHS processes is essential for multinational companies to ensure consistent safety practices and compliance.

    A comprehensive EHS management system can drive significant improvements in safety performance, compliance, and operational efficiency. 

    Data-driven decision-making and continuous improvement are essential for maintaining a competitive edge in the manufacturing industry.

    Careful planning, and a phased implementation, are essential for a successful EHS system deployment.

    The system must be flexible, and able to adapt to changing regulations, and company needs.

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