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Darling International

The Company

Testimonial

"Training is a critical component of our corporate Safety Management Program. PureSafety provides an effective tool to achieve our training goals, and we now have real measurable accountability with our managers. By implementing PureSafety, combining a superior training product and a superior training result, we have increased our employees' knowledge, skill, and safety awareness. The team at PureSafety has been incredible partners with customer service that is second to none."

Patrick McNutt
Director of Safety Management

In 1882, a Chicago family named Darling joined forces with the meatpacking firm of Swift & Co. to find markets for waste fat, bones, and other by-products. Three years later, the Darling family separated from the meatpacking division of the business to concentrate on what is known as "rendering" today and began expanding the company.

Today, Darling International, Inc. is America's leading provider of rendering, recycling and recovery solutions to the nation’s food industry. The company provides recycling and rendering services in which animal and food waste products are turned into useful commercial goods, including tallow, protein meals (meat and bone meal), and yellow grease. Darling also services the restaurant industry by removing used cooking oil and servicing grease traps. The company’s three-shift operation currently employs 1,200 people in 44 domestic locations.

The Challenge

Training Material and Traditional Training Methods
As a safety conscious company, Darling has long been dedicated to providing the proper training to its employees – mainly through the use of videos in a meeting format. Originally, televisions and VCRs were set up in each facility and employees were shown the training and then required to sign the roster when completed. While employees were shown on the roster as having viewed the required video(s), Darling wanted to measure the learning achieved by the training activities.

Training Consistency & Tracking
With 44 domestic locations and Darling’s entrepreneurial operating style, the company wanted to centrally manage training methodology and scheduling.

A Multi-Lingual Workforce
Nearly ten percent of Darling’s workforce speaks Spanish as a first language, so any training presentations, materials, and learning measurements had to be available in both English and Spanish.

A Large Fleet
Darling employs over 600 drivers throughout its 44 locations. Providing consistent, effective driver safety training to this group of employees is important due to the high cost of claims related to fleet accidents.

Three Shift Operations
A majority of Darling’s operations run around the clock, making it challenging to find time for training.

The Solution
In order to provide a more efficient method of delivering, tracking, managing and reporting on the company's safety training programs, Darling implemented the PureSafety Enterprise solution in 2001. Today, the company delivers at least one safety course or more per month to 1,000 Darling operation and management employees through a private-label version of the PureSafety LMS known as DarlingTrainer (www.darlingtrainer.com). Darling employees are able to take the training from home or work – whichever is easiest for them. Every PureSafety course is made available in both English and Spanish, providing for real and measurable transfer of knowledge to all Darling’s employees including the Spanish speaking workforce.

The Results

The PureSafety training solution is an integral tool in Darling's 5-part Safety Management Program. The program, which includes active participation on the part of Darling’s CEO Randall Stuewe, includes the following components:
  1. PureSafety Training
    1. One or more courses per month/per employee
    2. Focus on worker safety (safe production), OSHA essentials, and driver safety
    3. Reports provide for better management accountability

  2. Accountability - Monthly Score Card by plant location
    1. Includes several key metrics for quantitative results
    2. Drives a substantial component of management bonus

  3. Safety Management Activities
    1. Monthly inspections by General Managers
    2. Vehicle inspections by Transportation Managers
    3. Actively managing safe production through feedback

  4. Darling Observation Program
    1. Supervisors perform controlled observations of on-the-job employee behavior for specific tasks and provide feedback on safe and at risk behaviors. This process helps identify gaps between expectations and reality regarding safe production and training.

  5. Recognition Process
    1. Employees are recognized and rewarded quarterly at a minimum for exhibiting safety productive work habits
    2. Long-term employees are recognized and rewarded for continued success within the Safety Management System
Through its commitment to a comprehensive, consistent safety program, Darling has seen incredible results, including:
  • Decreased overall Lost Time Incident Rates by 59% over a 3-year period (see chart below)
  • Reduced its Fleet Accident Rates per 100,000 miles driven by an average of 34% over a 3-year period (see chart below)
  • Lower Insurance costs
  • A more focused and satisfied work force

Lost Time Incident Rates by Year
Fleet Accidents Per 100,000 Miles