Worthington Industries: Zero Injuries, Zero Harm – The Delta Plant’s Safety Excellence

Introduction

In 2004, Jody Willeman, a galvanizing line operator at Worthington Industries’ Delta, Ohio plant, suffered a severe foot injury while attempting a routine maintenance task. The incident highlighted the critical need for a safety culture that goes beyond compliance.

Fast forward to 2007: the Delta plant logged zero OSHA recordable injuries or illnesses and zero DART cases over 306,559.25 work hours—a remarkable feat in the high‑volume steel processing industry.

Incident Overview

During a quick repair on a high‑pressure air nozzle, a procedural error caused Willeman’s foot to become trapped between steel tubing and the machine frame. He described the moment as “the foot popped and cracked at least five times.” A maintenance technician’s timely intervention prevented a catastrophic loss.

Willeman’s recovery took two months in a stabilizing boot, underscoring the human cost of lapses in safety practice.

Delta Plant Facts

• Location: Delta, Ohio (25 miles SW of Toledo)
• Size: 426,000 sq ft
• Employees: 185 (14 maintenance workers, 1 maintenance manager)
• Production: 1.55 million tons of steel per year; galvanizing and pickling lines run 24/7, slitting line 24/7, 5–6 days/week
• Opened: 1997 on a former cornfield; 20 employees at inception
• Inventory turnover: full bay in 3 weeks

Safety Culture & Leadership

Worthington’s “Golden Rule”—treating customers, employees, investors, and suppliers as one would like to be treated—forms the ethical backbone of its operations. The 2001 revamp of the safety program introduced the Safe Works initiative, a centrally governed yet locally managed framework that ties safety to production, quality, and cost.

Executive Vice President George P. Stoe noted, “Safety is not a separate cost; it is integral to our profitability.” This philosophy is reflected in the plant’s zero injury record and the company’s broader safety metrics: a 55% reduction in OSHA recordables and a 73% drop in worker’s comp costs since 2001.

Safe Works Components

• BRITE (Business and Risk Improvement Techniques for Everyone) – a behavior‑based reinforcement program that uses peer observation, anonymous reporting, and incentive rewards to embed safe habits.
• Safety Council – cross‑departmental leaders who serve two‑year terms, drive policy, and maintain accountability.
• Root‑Cause Analysis – teams use fishbone diagrams, 5‑why, and FMEA to eliminate hazards at the source.
• First Response Team – 28 trained members who conduct monthly CPR/AED drills and maintain lightweight trauma bags.
• Training & Visual Aids – concise 15–30 minute modules, punch‑card tracking, PPE guides, and video boards.
• Take Five & SLAM – a five‑minute pre‑task safety check that encourages risk assessment and hazard mitigation.

Recognition & Awards

• Chairman’s Award (Zero recordables & zero DART) – Delta among 13 winners in FY2007
• President’s Award – for zero DART or significant safety improvement
• Safe Works Team Award – quarterly for accident‑free departments
• Safe Worker Award – quarterly for individuals with outstanding safety, attendance, and BRITE participation

Delta’s safety record has earned it a reputation as a “diamond” within Worthington, inspiring other plants to emulate its standards.

Continuous Improvement

Safety leaders emphasize that achieving zero is not a final destination but a milestone in an ongoing journey. “There’s no finish line,” says Safety Manager Rick Mitchell. “We constantly look for the next opportunity to improve.”

By embedding safety into everyday operations—through rigorous training, peer accountability, and proactive hazard removal—Worthington Industries’ Delta plant demonstrates that zero injuries are attainable and sustainable.

Take Five & SLAM in Action

STOP: Assess potential injuries to self and others, equipment damage, and optimal execution.

LOOK: Identify hazards from human, machine, and environmental interactions.

ASSESS: Evaluate likelihood and consequence of identified risks.

MANAGE: Mitigate risks through energy reduction, isolation, guarding, training, and PPE.

These principles are taught to all employees, visitors, and contractors, reinforcing a culture where safety precedes production.

Plant Recipients of the 2007 Chairman’s Award

• Delta, Ohio; Decatur, Ala.; Baytown, Texas; Denver, Colo.; Kapolei, Hawaii; Hutchins, Texas; Lenexa, Kan.; McDonough, Ga.; Phoenix, Ariz.; Stockton, Calif.; Wildwood, Fla.; Westerville, Ohio; Cleveland, Ohio

Worthington Industries continues to push the bar higher, striving for zero near‑misses and a safer future for all employees and stakeholders.