Safety Taken to the Extreme
Kaizen Snapshot
Setting: Dal-Tile manufacturing plants (Southern U.S.)
Challenge: Asbestos sampling under extreme conditions
Stakes: Worker safety, compliance, personal resilience
Approach: Strict protocols, long-duration sampling, extreme heat exposure
Outcome: Complete audit, deeper respect for safety discipline
Key Lesson: True safety work demands discipline, endurance, and respect for risk
The Situation
During my time at Dal-Tile, I worked as the environmental, safety, and mining liaison for 12 manufacturing plants.
There was little trust between the plants and the corporate safety group, so I was assigned to shadow a corporate environmentalist during asbestos audits.
His name was Richard. He wasn’t exactly customer friendly, but he was meticulous.
What Was Getting in the Way
Asbestos sampling wasn’t done during normal shifts.
We worked nights, weekends, and off-hours, when plants were quiet.
Richard wore a full Tyvek suit in the middle of summer in the South.
I was told to stay at least 30 feet away.
Even from 30 feet, I was uncomfortable.
Going Where the Risk Was
At one plant, Richard climbed on top of a ceramic tile dryer, hundreds of feet long and extremely hot.
I followed him.
The surface temperature was between 120 and 140 degrees. He was sealed in Tyvek. I was not. I have no idea how he tolerated the extreme heat. I was melting.
We worked 14–16 hours per plant. In four days, we slept less than 12 hours total.
What Changed
Richard never slowed down.
He followed every protocol.
He documented everything precisely.
It was one of the most physically demanding and disciplined safety efforts I’ve ever witnessed.
And I learned something important about myself.
The Takeaway
I gained a deep respect for the rigor behind real safety work and clarity that this wasn’t my long-term path.
Safety isn’t a slogan. It’s discipline under pressure.
Why This Matters
Many organizations talk about safety. Few truly understand the rigor required to protect people in high-risk environments.
Discipline saves lives.
Want Safety That Actually Sticks?
If safety feels reactive instead of disciplined, Kaizen can help build systems that protect people consistently.