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Business ofSafety

Business of Safety

The Cost
of Safety
Cost analysis model helps build business case for safety
By Michael Behm, Anthony Veltri and Ilene K. Kleinsorge

S SH&E PROFESSIONALS HAVE OFTEN become vic-


tims of their own success in achieving regulatory
compliance; many business executives view beyond-
compliance spending as a fruitless exercise (Soyka
and Feldman 61). Compounding this problem is the
ness (Adams 23). Cost analysis models are needed to
help SH&E professionals measure, analyze and com-
municate safety strategies in business terms. This arti-
cle details one such model from the quality
management literature.
fact that SH&E professionals seldom use business
models or speak in business terms. Safety jargon is Relationship Between Safety & Quality
often considered irrelevant and inconsistent with Many authors, including Manzella, Blair, Weinstein
Michael Behm, CSP, is a Ph.D. candidate and
standard business terminolo- and Manuele, have made clear the link between qual-
graduate teaching assistant in Oregon State
gy and objectives (Hill 25). If ity management and safety management. Upon
Universitys Environmental Health and Safety
the SH&E department does reviewing quality management literature, Manuele
Program. He has more than 10 years experience
not understand the financial concluded that the word quality is interchangeable
in occupational safety and industrial hygiene.
loss to an organization, sen- with the word safety, and his premise remains
Behm received a B.S. from Millersville University
ior management will find sound (12). To show how safety mirrors the quality
and an M.S. from Temple University. Current
it difficult to understand function, Manuele inserted safety for quality in
research interests include safety through design
the financial benefit the the following statement:
safety department provides
and safety management. He is a professional When quality (safety) is seamlessly integrated
(LaBelle 38). The end result is
member of ASSEs Columbia-Willamette Chapter. into the way an organization operates on a daily
that SH&E issues are not
Anthony Veltri, Ph.D., is an associate professor fully integrated into the stan- basis, quality (safety) becomes not a separate
of environment, safety and health sciences at dard business framework; as activity for committees and teams but the way
Oregon State University. He specializes in assessing a result, management views every employee performs his or her job (203).
SH&E strategy and its economic impact on a firms the SH&E function in terms The similarities between safety and quality in the
competitive performance. Current research is of a compliance-oriented, construction industry have been summarized as well.
aimed at making the business case for safety, reactive strategy. Coble, et al introduced the cost of quality (COQ)
profiling the cost burdens and profitability The fact that SH&E pro- model as a tool that could be applied for evaluating
potential of SH&E activities. A professional fessionals need to build a safety costs (160).
member of ASSEs Columbia-Willamette Chapter, business case for their efforts The research presented in this article builds on
Veltri is the faculty advisor for ASSEs Oregon is well-documented (Hill 19). these concepts and describes how the COQ model can
State University Student Section. Knowledge in business and be applied to safety. A case study is provided to
Ilene K. Kleinsorge, Ph.D., is the Sara Hart accounting helps SH&E demonstrate how costs associated with managing an
Kimball Dean of the College of Business at professionals speak to man- ergonomics program at two organizations were col-
Oregon State University, where she directs a agement and maintain credi- lected, analyzed and interpreted. SH&E professionals
program with more than 2,100 students, including bility (Blair 32). To work can use this model to track, analyze and report SH&E
92 M.B.A. students. Kleinsorge earned her B.S. more effectively with other function-related costs. Thus, the model can help them
from Emporia State University and her Ph.D. from financial and operations make the business case by driving decision making
the University of Kansas. An OSU faculty member management personnel, it and operating action within the SH&E function.
since 1987, Kleinsorges teaching and research has been suggested that
focuses on cost and managerial accounting SH&E professionals must COQ Framework & Its Application to Safety
systems, with emphasis on multinational become better versed in the The COQ framework consists of four main cost
companies and healthcare. common language of busi- activity groups: prevention, detection, internal fail-
22 PROFESSIONAL SAFETY APRIL 2004 www.asse.org
ures and external failurester-
minology that is well-suited to Figure
Figure 1 1
the practice of safety.
Cost of Quality (Safety)
Prevention
Prevention activities are
designed to keep defects from
occurring. Such activities are
viewed as optimal methods of
averting downstream defects.
They are discretionary, budget-
ed actions intended to prevent
failures. SH&E professionals
undertake prevention activities
to avoid losses such as employ-
ee injuries and illnesses, and
property damage. Examples of
such activities are safety func-
tion involvement in the design
of new products, processes,
technologies and services; em-
ployee training; and safe mate-
rial procurement.
Detection
Detection activities, also re-
ferred to as appraisal activities, involve inspection of agencies and public-image issues. Public-image costs
the work in progress to minimize defects. An organi- arise from the reputation of being an unsafe place to
zation conducts these activities because it under- work, which can be detrimental to business. For
stands that not all defects can be prevented or that example, a January 2003 Public Broadcasting Service
some are too costly to prevent. It develops proce- Frontline special entitled A Dangerous Business
dures and employs quality control inspectors to reported on the egregious safety record of McWane
verify standards. The key distinction between pre- Inc. If product purchasers or end users boycott a par-
vention and detection activities is that the former are ticular organization because of its poor safety record,
more likely to avert a defect, but are typically more then the cost of product not sold as a result would be
costly, while the latter identify and correct a defect classified as an external failure cost.
after it has occurred. In the analysis of overall pro-
gram effectiveness, prevention and detection costs Analyzing the Cost of Safety
are combined because they are both proactive meas- The cost of safety (COS) model evaluates trends in
ures taken to minimize failures. Their combined cost total safety costs over time. The relationships among
is compared to total failure costs. The SH&E function safety cost categories offer a useful tool for tracking
is responsible for various detection activities, includ- and analyzing previous costs and for assisting with
ing safety inspections, industrial hygiene monitor- the budgeting of future SH&E initiatives. An optimal
ing, safety committee activities and behavior-based equilibrium point theoretically exists, where total
safety observations. prevention and detection costs equal total failure
Internal Failure costs (Chalos 101). This point is dynamic and is
Internal failures are costs associated with rework- found through linear regression. The theoretical opti-
ing, scrapping and other performance defects that mal equilibrium point suggests a discretionary bud-
occur before the product is passed on to the cus- geted amount for prevention and detection costs that
tomer. Internal failures occur inside the facility; they will still yield failures, but at a level such that the sum
are the costs an organization tries to avoid by man- of total SH&E costs is minimized, or optimal.
aging appropriate prevention and detection activi- Figure 1 depicts this model, which is adapted
ties. Examples of safety-related internal failures are from quality management literature (Chalos 102). As
workers compensation (WC) costs, incident investi- Figure 1 shows, when prevention and detection
gations, costs of retraining new employees and pro- costs are low, the cost of failure will be high. As pre-
vision of PPE after an injury occurs. vention and detection costs increase, failure costs
should decrease, since more is spent to counteract
External Failure risk. The COS model must be distinguished from the
External failures include warranty costs and prod- notion that an organization should have a goal of
uct recalls. These costs occur once the product leaves zero accidents. Beyond a certain level of very high
the facility and is passed on to a customer or a distrib- safety (quality), the goal of zero defects (accidents)
utor. Safety-related external failures include regulato- becomes very costly to attain and maintain. For the
ry fines, administrative costs associated with outside SH&E profession, the model shows that prevention
www.asse.org APRIL 2004 PROFESSIONAL SAFETY 23
Table
Table 1 1
zation must determine what
level of risk is acceptable, what
strategies are taken to counter-
Cost of Ergonomics Worksheet Example act risk and at what level these
strategies will be financed. As
Total Operating Costs (TOC) Year 1 Year 2 Year 3 with most financial tools, it is
Prevention up to the organization to inter-
pret the data according to
Employee ergonomic training. internal standards and man-
Staff ergonomic training. agement philosophy in order to
Proactive workstation evaluations and modifications. make appropriate financial de-
Total prevention costs cisions. The COS model does
not dictate those decisions; it
Total prevention costs as % of TOC simply presents financial infor-
Detection mation that can be used to
Ergonomics safety committee. drive decision making and
operating action. Interpretation
Workstation evaluation and modifications from employ- of each COS model is individu-
ee concerns or discomforts but before injury occurs. alized, as the following case
Total detection costs study illustrates.
Total detection costs as % of TOC Case Study:
Failures (Internal & External) Ergonomics Programs
The costs of ergonomics-
Workers compensation costs associated with ergonomics
related activities at two or-
injuries and illnesses.
ganizations were collected,
Workstation evaluations and modifications after injury analyzed and interpreted as
occurs. part of this research. Company
Indirect costs of time away from jobretraining, lost A is the finance department of
work, etc. a large multinational compa-
Total failure costs ny, with approximately 1,600
employees. Company B is a
Total failure costs as % of TOC light-manufacturing facility
with approximately 300 em-
and detection costs must be substantially increased ployees. Both companies describe ergonomics-relat-
to achieve zero accidents or to get close to zero acci- ed issues as a major safety and cost concern.
dents. According to Chalos, While slogans such as Ergonomics costs, as opposed to overall SH&E pro-
Zero Defects and Quality is Job 1 are appealing, gram costs, were analyzed for this study.
such goals are not attainable without significant
Data Collection
incurrence of prevention and appraisal costs (100).
The two companies were asked to retrospectively
The optimal-cost approach minimizes accidents
document costs associated with their ergonomics
(failures) to the point that an organization spends
programs over a three-year period. Each received a
only what is necessary to minimize overall costs
description of the research and a worksheet with
associated with safety. This philosophy may be in
examples of ergonomics costs broken into the cate-
sharp contrast to the prevailing view within the gories of prevention, detection, internal failures and
SH&E profession. From a financial viewpoint, how- external failures. Each company was asked to pro-
ever, the COS model provides the manager with a vide estimated costs for each line item (if applicable),
structure for analyzing costs, preparing budgets and add any line item it deemed appropriate and pro-
setting realistic goals (for performance, cost, etc.). vide estimated total operating costs for each year.
This model is a short-term model, so a diminishing Total operating costs provided a baseline by which
rate of return would not be experienced; therefore, it to normalize the data and make costs incurred in
must be monitored annually. each year comparable as percentages. Table 1 pres-
The model also makes sense from a risk manage- ents an example of the worksheet and line items.
ment standpoint. Some risk is inherent in all activi- For these case studies, costs associated with
ties (Manuele and Main 57). Certain risks cannot be workstation evaluations and modifications were
eliminated or nearly eliminated without very high classified according to the timing of those costs
cost, while other risks can be eliminated with little (Table 1). For example, if a company decided to
effort and at low cost. The purpose of any cost analy- evaluate and modify workstations within an entire
sis exercise is to identify these low-hanging fruit. department because it had identified ergonomics
The COS model recognizes that some risk must be risk factors, this cost was classified as prevention. A
considered acceptable for an organizations financial workstation evaluation and modification prompted
stability. One should also recognize that each organi- by an employee concern or discomfort was classified
24 PROFESSIONAL SAFETY APRIL 2004 www.asse.org
as detection. The difference between the two is that in the COS model? For example, if a new piece of
in the prevention activity the organization made a equipment is purchased and it is known that it will
discretionary attempt to prevent failure; in the detec- reduce ergonomics risk factors, should its cost be
tion activity, the employee or his/her supervisor included as an ergonomics cost? The answer will
detected a symptom and requested intervention. depend on the cost object, which is defined as any-
The same activity was classified as an internal failure thing for which a measurement of cost is desired
if it occurred after an employee sustained an (Horngren, et al 30). If the cost object is safety, then it
ergonomic injury, missed work time or experienced would be included in the cost of safety. However, an
some other type of failure. Since neither company organization may include the same cost in multiple
reported external failure costs associated with its cost analyses (e.g., safety and quality).
ergonomics program, internal and external failures What about the base costs of WC and other safe-
were combined into one category; they are hereafter ty-related insurances? A company needs insurance
referred to as failure. to be in business, so should the base cost be includ-
ed in the model? Again, it depends on several fac-
Challenges in Collecting the Costs of Safety tors. If the goal is to report, track and analyze all
In the process of collecting and quantifying costs associated with an organizations safety pro-
ergonomics costs, several challenges and observa- gram, then this cost should be included. However, if
tions were identified relative to the COS model. As the goal is to analyze specific program costs, such as
in many organizations, Company Bs ergonomics those of an ergonomics program, then it would not
costs were difficult to locate and calculate with accu- be appropriate to include such fixed costs. The deci-
racy. Time and energy were required to verify each sions made in response to these challenges and oth-
line item. The fact that these costs were not readily ers will depend on the goal of the cost analysis.
available was a strong indicator that those
costs had not been fully analyzed within
the company. Table 2
Table 2
It is important to note that the time and
costs associated with data gathering must Company A: Cost-of-Ergonomics Data*
not outweigh the benefit of analyzing
those costs. Thus, some organizations Internal External Total
may decide to establish the appropriate Year Prevention Detection Failure Failure Costs
cost-collecting mechanisms and gather
1 0 0.00008 0.00248 0 0.00256
data prospectively rather than retrospec-
tively. At startup or when accounting sys- 2 0.00032 0.00005 0.00203 0 0.00240
tems change, organizations should 3 0.00041 0.00005 0.00143 0 0.00189
include the SH&E function as they create
the chart of accounts. *as a percentage of total operating costs
Another issue was whether
to include the cost of safety
staff salaryand, if so, where Figure 2
Figure 2
to include it. As with all costs,
this would be up to the indi- Company A: Costs of Ergonomics
vidual organization or manag-
er. If the goal were to report all
SH&E costs to management,
then it would be best to
include staff salary.
One method of inclusion
would be to estimate the per-
centage of time spent perform-
ing prevention, detection and
failure activities, then to allo-
cate the salary based on that
calculation. In this case, SH&E
staff salaries were not included
since the goal of the participat-
ing companies was to examine
ergonomics activities and their
financial impact.
Other challenges were also
encountered. Should certain
capital expenditures for proc-
ess improvement be included
www.asse.org APRIL 2004 PROFESSIONAL SAFETY 25
Figure
Figure 3 3
Company A: Optimal Equilibrium Point

Analysis: Company A costs. Furthermore, if the program is properly man-


Table 2 shows Company As reported ergonomics aged, its overall cost should decrease. Note that the
costs as a percentage of total operating costs for the optimal point in this case is actual, not theoretical.
four COS activities and as total cost of the program. Because of this companys previous reactive strategy
Figure 2 illustrates the trend and relationship of these and its subsequent financial decisions, it is a strong
costs over the three-year period. This companys possibility that the optimal point is fairly exact. When
ergonomics program was not well-developed prior to Company A did act, it did so in a well-structured,
Year 1 and provided only a reactive approach to properly financed manner. It took the time to analyze
ergonomics cost and injury control. The organization the trade-offs between prevention and detection
recognized that ergonomics-related costs and acci- costs and failure costs. The result is a decreasing
dents had become a financial issue. In Year 1, it decid- trend in overall ergonomics costs and an expected
ed to evaluate and modify every workstation over the continued decrease in subsequent years.
subsequent two-year period, beginning with those
workstations and tasks identified as higher risk. Specific Recommendations for Company A
As Figure 2 shows, the total cost of this ergonom- Company A has already analyzed each worksta-
ics program has decreased in each of the three years. tion from an ergonomics perspective. In the short
Closer analysis indicates that the sum of prevention term, it may be able to achieve little more in terms of
and detection costs increased, whereas total failure prevention activities except with respect to worksta-
costs decreased. This trend demonstrates that preven- tions for new employees, or new workstations or
tion and detection activities budgeted for and under- tasks added for current employees. Furthermore, pre-
taken have successfully influenced failure costs. vious prevention activities will continue to reduce
Figure 3 demonstrates this trend and provides a failures in subsequent years. These preventive meas-
theoretical optimum cost of the ergonomics program. ures must be monitored to ensure continued effec-
It suggests that in future years Company A should tivenesswhich is a detection activity.
increase budgeted activities for ergonomics preven- An ergonomics safety committee was the only
tion and detection activities. This increase in discre- line item detection activity in years 2 and 3. To reach
tionary budget should produce a decrease in failure the goal of decreasing the overall costs of ergonom-
26 PROFESSIONAL SAFETY APRIL 2004 www.asse.org
ics, Company A should consider increasing detec- are increasing, but have not yet met or surpassed
tion activities in order to identify risk factors associ- failure costs. Company A is a classic case of how
ated with the prevention activities previously strategic funding of prevention and detection expen-
funded. Any additional SH&E investment would ditures can produce a decrease in failures and a
assume a similar rate of return and would be justi- decrease in overall program costs.
fied and analyzed as any other investment. By contrast, in Company B, prevention and detec-
Specific recommendations for Company A: tion costs began high, while failure costs were com-
1) Ensure that the ergonomics committee is being paratively low. Failure costs then dramatically
properly used, that its role and functions are proper- increased in Year 3. Prevention and detection expen-
ly defined and that the committee is budgeted ditures did not produce a decrease in failure costs.
accordingly (detection). Figure 5 shows the theoretical optimal point for
2) Hire an ergonomics consultant to periodically Company B. Because only three data points are
evaluate modified workstations (detection). available and because this company has not previ-
3) Implement an employee self-awareness pro- ously quantified and analyzed ergonomic costs, use
gram designed to promote early detection of any of the theoretical optimal point would be ill-advised,
ergonomics-related problems, issues or concerns as it is highly speculative and will be quite dynamic
(detection). in subsequent years.
4) Implement an ergonomics education program It is not suggested that this be the only model used
that addresses employees off-the-job activities and to develop a discretionary budget for the ergonomics
hobbies (prevention). program. Company B needs to properly evaluate risk
Analysis: Company B factors and develop a fiscally responsible strategy to
Table 3 shows Company Bs reported
ergonomics costs as a percentage of total
operating costs for the four COS activities
Table 3
Table 3
and as a total cost of the program. Figure
4 illustrates the trend of these costs over Company B: Cost-of-Ergonomics Data*
the three-year period.
As noted, this company had trouble Internal External Total
calculating and verifying specific ergo- Year Prevention Detection Failure Failure Costs
nomics costs. It had established an 1 0.00028 0.00022 0.00029 0 0.00079
ergonomics program prior to Year 1, yet
costs were not effectively analyzed or 2 0.00043 0.00022 0.00032 0 0.00097
tracked. The company financed employee 3 0.00023 0.00034 0.00073 0 0.00130
training and modified workstations.
*as a percentage of total operating costs
Figure 4 shows the total cost of
ergonomics steadily rising over the three-
year period. Failure costs have
increased, with a significant Figure 4
Figure 4
increase in Year 3. The compa-
ny attributes this increase to Company B: Costs of Ergonomics
one large WC claim and ex-
pects costs in subsequent years
to decrease. However, the data
indicate cause for continued
concern. One can conclude that
the allocation of budget to pre-
vention and detection activities
has not been fully effective.
These activities did not ade-
quately minimize the risk of
ergonomics-related injuries,
and, therefore, should be re-
evaluated. If risk is not ade-
quately controlled through
proper funding, additional
and costlyfailures are likely.
When these two companies
are compared, opposite trends
are apparent. In Company A,
failure costs started high and
are decreasing; prevention and
detection costs started low and
www.asse.org APRIL 2004 PROFESSIONAL SAFETY 27
Figure
Figure 5 5
Many SH&E in-
vestments are made
to reduce risk fac-
Company B: Optimal Equilibrium Point tors for which acci-
dents have not yet
occurred and whose
costs are invisible.
Deming recognized
the importance of
understanding
these invisible fig-
ures and contended
that managing an
organization using
only visible figures
is one of the seven
deadly diseases that
afflicts most West-
ern companies (97-
98). If the purpose of
using the COS
model is to report
all costs associated
with the program,
then contingent lia-
bility modeling is
not practical. How-
ever, when the goal
is to understand the
interrelatedness of
costs and to prepare
counteract that risk. For example, consider whether discretionary budg-
data from only years 1 and 2 were available for ets, then invisible costs must be considered.
Company B; these data would suggest analyzing Specific Recommendations for Company B
prevention and detection costs and possibly reducing Company Bs data highlight the significance of
them to meet the cost of failures. Had that decision not fully understanding costs associated with a spe-
been made, the risk associated with the incident in cific SH&E program. If ergonomics cost data are not
Year 3 would have still existed. Therefore, the COS collected and analyzed, prevention and detection
model should be used in conjunction with other budgetsand, thus, activitieswill not be as effec-
management practices to develop discretionary tive as they could be. Furthermore, this case study
budgets for Company Bs ergonomics program. indicates the disconnect of the SH&E function from
Another financial consideration is to evaluate any other business functions that are tracked, analyzed
cost savings associated with not making an invest- and funded for business success. Data from
ment to counteract the injury in Year 3. If the present Company B also reveal the impact that one injury can
cost of preventing an injury is deemed to be greater have on an SH&E programs financial statement.
than the cost of the injury, it would not make finan- The data suggest that prevention and detection
cial sense to make the investment. However, such an activities should be re-evaluated for increased effec-
investment may certainly make sense from a tiveness. Company B needs to reorganize these
humane and business ethics standpoint. Further- activities to better minimize the risk of future fail-
more, this same risk factor likely affects more than ures while not drastically increasing their discre-
just the one employee who was injured. tionary budget. Furthermore, the fact that the costs
These observations suggest the use of contingent were difficult to collect suggests that the data may
liability modeling (see sidebar pg. 29) to show that not be as accurate as stated. Specific recommenda-
prevention and detection activities were necessary tions for Company B:
to prevent failures even if they had not yet occurred. 1) Use the prevention and detection budget more
Discussions with business researchers indicate that for engineering controls than for training. The pro-
this method of evaluating potential failure costs gram has been heavily weighted toward training;
within the COS model is plausible, but must be however, training and behavior modification are
applied prudently. As with any financial tool, con- often erroneously applied as solutions to problems
tingent liability data must be used consistently year and have limited effectiveness when incident causal
to year, and the numbers must be realistic and make factors are derived from workplace and work
financial sense. method design decisions (Manuele 19).
28 PROFESSIONAL SAFETY APRIL 2004 www.asse.org
2) Begin to track all SH&E-program-related costs precisely why the SH&E function gets left out of
so that the activities can be analyzed from a financial decision making in reactive organizations or during
standpoint. By knowing the true costs of safety, the an economic downturn, when organizations focus
organization can plan and budget for the necessary solely on historically value-added activities.
activities to reduce failures across all SH&E initia- The case study illustrates a method of using the
tives, including ergonomics. COS model to analyze ergonomics costs. This model
has applications to any other SH&E program. Other
Conclusions potential uses:
The contrast between Company A and Company B 1) Analyze total SH&E costs in a specific depart-
highlights the importance of proactively analyzing ment, facility or corporation.
and funding SH&E programs rather than taking a 2) Compare or benchmark SH&E costs across
reactive approach. For organizations to go beyond departments or facilities (as long as costs are meas-
compliance and truly influence and improve employ- ured in the same way). This exercise may reveal spe-
ee safety, SH&E professionals must make the business cific prevention and detection activities that truly
case for those strategies deemed appropriate to coun- impact failures in a cost-effective manner.
teract risk. The financial toolset that SH&E profession- 3) Track and report SH&E-related costs both
als use must be ever-evolving, yet remain congruent internally and externally, such as in an organiza-
with their organizations business strategies. tions annual report.
The overall cost of ergonomics for both compa- The COS model is not perfect, but it can be used
nies may not be very high compared to overall oper- as a foundation to make business sense of the SH&E
ating costs, and this may be the case for other function. Some costs, such as prevention and detec-
companies as well. In these examples, the overall tion activities, are easily quantified, while failure
cost of ergonomics is approximately $1.00 to $2.50 costs may be difficult to quantify and estimate. This
per $100,000 of total operating costs. When model provides a financial tool that an organization
approached from this view, the analysis of costs can use to drive decision-making and operating
associated with the programs may seem trivial, action within the safety function. In addition, the
especially when humanitarian and compliance con- COS model can be used to make the business case
siderations are the primary seller to upper manage- for the safety function so that SH&E professionals
ment with respect to budgetary decisions that affect can communicate more effectively with senior-level
SH&E initiatives. However, the exclusive use of executives about safety activities and their purpose
these customary approaches to justify initiatives is within the organization.
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www.asse.org APRIL 2004 PROFESSIONAL SAFETY 29

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